Download FWE200DH Dust Concentration Measuring Device

OPERATING INSTRUCTIONS
FWE200DH
Dust Concentration Measuring Device
Description
Installation
Operation
Document Information
Described Product
Product name: FWE200DH
Document ID
Title:
Part No.:
Version:
Release:
Operating Instructions FWE200DH
8016686
1.0
2014-05
Manufacturer
SICK AG
Erwin-Sick-Str. 1
Telephone:
Fax:
E-mail:
· D-79183 Waldkirch · Germany
+49 7641 469-0
+49 7641 469-1149
[email protected]
Place of Manufacture
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Trademarks
MS-DOS is a Microsoft Corporation trademark. Windows is a
Microsoft Corporation trademark.
Other product names used in this document may also be
trademarks and are only used for identification purposes.
Original Documents
The English edition 8016686 of this document is an original
document from SICK AG.
SICK AG assumes no liability for the correctness of an
unauthorized translation.
Contact SICK AG or your local representative in case of doubt.
Legal Information
Subject to change without notice.
© SICK AG. All rights reserved.
2
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Warning Symbols
Hazard (general)
Hazard by voltage
Hazard through laser beam
Warning Levels / Signal Words
DANGER
Risk or hazardous situation which will result in severe personal
injury or death.
WARNING
Risk or hazardous situation which could result in severe personal
injury or death.
CAUTION
Hazard or unsafe practice which could result in personal injury or
property damage.
NOTICE
Hazard which could result in property damage.
Information Symbols
Important technical information for this product
Supplementary information
Link to information at another place
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
3
Contents
4
1
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1
1.1.1
1.1.2
1.1.3
1.1.4
Main safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazard through hot and/or aggressive gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazard through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazards through laser beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazard through moving parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3
Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4
Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1
2.1.1
2.1.2
System features and application areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System features and advantages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Application areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
FWE200DH operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isokinetic behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scattered light measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic function check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.4.1
2.3.4.2
2.3.4.3
2.3.4.4
2.3.5
2.3.6
2.3.6.1
2.3.6.2
2.3.6.3
2.3.6.4
2.3.6.5
Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sample gas probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Extraction and return hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Measuring and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermo cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Extended calibration function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Blower unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Backpurge unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Heated extraction hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remote unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cover at the bottom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test equipment for linearity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3
Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1
Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2
3.2.1
3.2.2
3.2.3
3.2.4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the measuring and control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the blower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the remote unit option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
10
10
35
35
36
38
39
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
17
17
18
18
19
19
Contents
3.3
3.3.1
3.3.2
3.3.2.1
3.3.2.2
3.3.3
3.3.4
3.3.5
Subject to change without notice
4
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connecting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Connecting cables for digital, analog and status signals . . . . . . . . . . . . . . . . . . . 42
Connecting the blower unit and supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fitting and connecting the Interface module option. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the backpurge option (only necessary when ordered separately) . . . . . . 47
Connecting the remote unit option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Start-up and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1
4.1.1
4.1.2
4.1.3
Putting the FWE200DH into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Starting the FWE200DH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fitting the sample gas probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2
4.2.1
4.2.2
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.3.4
4.2.3.5
4.2.4
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installing the operating and parameter program SOPAS ET . . . . . . . . . . . . . . . . . . . . 55
Connecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configuring the interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connecting using the “Network Scan Assistant” tab . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting using the “Connection Wizard” menu (valid as from SOPAS ET
Version 02.32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Select device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3
4.3.1
4.3.2
4.3.3
4.3.3.1
4.3.3.2
4.3.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
Setting standard parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Setting “Maintenance” mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Changing function parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Change temperature settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Define limit value for the flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Set the suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Setting the function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Setting the analog output parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Setting the analog input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Setting the response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Defining regression coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Calibration for dust concentration measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4
4.4.1
4.4.1.1
4.4.1.2
4.4.1.3
4.4.1.4
4.4.1.5
4.4.2
4.4.2.1
4.4.2.2
4.4.2.3
Setting the Interface module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Modbus TCP module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check MCU settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Installing the configuration program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Integrating the Modbus module in the network. . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Configuring the Modbus module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Checking the functional capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Setting the Ethernet module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Assigning the Ethernet module a new IP address . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Assigning the new IP address to SOPAS ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.5
Activating the backpurge option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
5
Contents
6
4.6
4.6.1
4.6.2
4.6.3
4.6.3.1
4.6.3.2
4.6.4
Operating/setting parameters via the LC-Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Sample gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Analog outputs / inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Using SOPAS ET to modify display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5
Maintenance
5.1
5.1.1
5.1.2
5.1.3
5.1.4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Maintenance contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Auxiliary means required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Setting “Maintenance” mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Cleaning the inlet nozzles on the thermo cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cleaning the ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the suction nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cleaning the intermediate nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cleaning the sample gas probe and extraction and return hoses . . . . . . . . . . . . . 117
Cleaning the swirl chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Cleaning the optical surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Checking / replacing the filter element of the blower unit . . . . . . . . . . . . . . . . . . . . 120
5.3
Putting the measuring system out of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6
Troubleshooting and Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.1
6.1.1
6.1.2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Display of warning and malfunction messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2
6.2.1
6.2.2
6.2.3
Warning and error messages in SOPAS ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Measuring sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.2
7.2.1
7.2.2
7.2.3
7.2.4
Dimensions, Part Nos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Sample gas probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Measuring and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Blower unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Remote unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Weatherproof cover for blower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Device check accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Contents
Consumable parts for 2-years operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Measuring sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Blower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
8
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.1
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.2
Standard settings FWE200DH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Subject to change without notice
7.4
7.4.1
7.4.2
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
7
Subject to change without notice
Contents
8
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Important information
FWE200DH
1
Important information
Subject to change without notice
Main safety information
Intended use
Responsibility of user
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
9
Important information
1. 1
Main safety information
1.1.1
Hazard through hot and/or aggressive gases
WARNING: Danger from exhaust gas
Hot and/or aggressive gases can escape on gas-carrying system components
(sample gas probe, gas hoses, thermo cyclone, measuring unit, ejector) and
cause severe injuries to unprotected users.
 Switch the measuring system off before starting any work.
 Always use suitable protection equipment (protective clothing, protective
mask) when working.
 Let gas-carrying and hot system components cool down sufficiently before
touching or use protective equipment.
 Only remove or install the sample gas probe on equipment with gases
detrimental to health, high temperatures or high pressure when the
equipment is at a standstill.
On equipment with low hazard potential (no danger to health, ambient pressure, low
temperatures), the sample gas probe can be installed or removed while the equipment is in
operation providing the valid regulations and safety regulations of the equipment are
observed, and necessary and suitable protective measures are taken.
1.1.2
Hazard through electrical equipment
WARNING: Danger through power voltage
The FWE200DH measuring system is operational equipment for use in
industrial installations.
 Switch any live parts with a risk of electric shock disconnected from the
mains and potential-free first before starting the work.
 Refit any contact protection previously removed before switching the main
supply voltage back on again.
1.1.3
Hazards through laser beam
1.1.4
Hazard through moving parts
WARNING: Hazard through moving parts
The optional backpurge unit has a ball valve actuated electrically that can
cause severe bruising when not used properly.
⊗ Do not insert any body parts (fingers) or objects into the openings during
actuation.
10
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
WARNING: Hazards through laser beam
The sender/receiver unit of the FWE200DH uses a laser with protection
class 2.
⊗ Never look directly into the beam path
⊗ Do not point the laser beam at persons
⊗ Do not move any reflecting objects into the beam path.
Important information
1.2
Intended use
Purpose of the device
The FWE200DH only serves continuous measurement of dust concentrations in wet gases.
Correct use
 Use the device only as described in these Operating Instructions. The manufacturer
bears no responsibility for any other use.
 Observe all measures necessary for conservation of value, e.g., for maintenance and
inspection and/or transport and storage.
⊗ Do not remove, add or modify any components on or in the device unless described and
specified in the official manufacturer information. Otherwise
– the device could become dangerous
– the manufacturer’s warranty becomes void
Subject to change without notice
Restrictions of use
The FWE200DH measuring system is not approved for use in potentially explosive
atmospheres.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
11
Important information
1. 3
Responsibility of user
 Only put the FWE200DH into operation after reading the Operating Instructions.
 Observe all safety information.
 If anything is not clear: Please contact SICK Customer Service.
Designated users
All operators of the FWE200DH should be specifically trained on this device, knowledgable
of relevant regulations, and able to assess potential hazards related to its operation.
Equipment safety
The safety of a system in which the FWE200DH is integrated is the responsibility of the person operating the system.
Correct use
• This Manual presumes that the FWE200DH has been delivered as specified during
project planning (i.e., based on the SICK application questionnaire) and the relevant
delivery state of the FWE200DH (→ delivered System Documentation).
 Contact SICK Customer Service if you are not sure whether the FWE200DH
corresponds to the state defined during project planning or to the delivered system
documentation.
 Use the FWE200DH only as described in these Operating Instructions. The manufacturer bears no responsibility for any other use.
 Perform the specified maintenance work.
⊗ Do not carry out any work or repairs on the FWE200DH not described in this Manual.
Do not remove, add or modify any FWE200DH components unless described or
specified in the official manufacturer information.
Otherwise:
– the manufacturer’s warranty becomes void
– the FWE200DH could become dangerous
Special local conditions
 Follow all local laws, regulations and company-internal operating directives applicable
at the installation location.
Subject to change without notice
Electric connection
 It must be possible to switch the power supply of the FWE200DH off using a power
isolating switch/circuit breaker in accordance with EN 61010-1.
12
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Important information
1.4
Safety information and protective measures
Protection devices
NOTICE:
Suitable protection devices and safety equipment for persons must be
available according to the respective hazard potential and be used by the
personnel.
Preventive measures for operating safety
NOTICE:
The user must ensure that:
 Neither failures nor erroneous measurements can lead to operational
states that can cause damage or become dangerous
 The specified maintenance and inspection tasks are carried out regularly
by qualified, experienced personnel.
Recognizing malfunctions
Every deviation from normal operation is to be regarded as a serious indication of a
functional impairment. These are, amongst others:
 Warning displays (e.g., heavy contamination)
 Significant drifts in measured results
 Power input above the rated value of the device
 System component temperatures above normal operating values or the fixed limit
values
 Monitoring devices triggering
 Smells or smoke emission
Subject to change without notice
Avoiding damage
NOTICE:
The operator must ensure the following to avoid malfunctions that can
indirectly or directly lead to injuries to persons or material damage:
 The FWE200DH is connected to a safe (uninterrupted) power supply,
 The responsible maintenance personnel are present at any time and as
fast as possible
 The maintenance personnel are adequately qualified to react correctly to
malfunctions of the measuring system and any resulting operational
interruptions (e.g., when used for measurement and control purposes)
 The defective equipment is switched off immediately in case of doubt
 Switching off the equipment does not indirectly cause further malfunctions
 When the equipment is at a standstill, the FWE200DH is either operated
furthermore or put out of operation → p. 121, §5.3).
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
13
Subject to change without notice
Important information
14
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Product Description
FWE200DH
2
Product Description
Subject to change without notice
System features and application areas
FWE200DH operating principle
Device components
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
15
Product Description
2. 1
System features and application areas
The FWE200DH measuring system serves continuous measurement of dust
concentrations up to 200 mg/m³ (typical application area) in wet gases (temperature
below dew point) with a resolution to approx. 0.1 mg/m³. It can be used in a wide range of
applications and features low installation effort and simple handling.
2.1.1
System features and advantages
 Extraction of a partial gas flow from the gas duct
 Drying and overheating the wet partial gas flow with adjustable electrical heating for
constant sample gas temperature to rule out measurement errors caused by droplets
existing before
 Gas extraction and return with one sample gas probe which means only one mounting
flange is required
 Dust content determination using scattered light measurement for low to medium dust
concentrations
 Compact measuring system design means simple assembly and installation
 Operating values and system status displayed on an LC-Display
 Flow monitoring with integrated differential pressure measurement
 Simple configuration and operation using user-friendly software
 Self-control through automatic function check (→ p. 19, §2.2.5)
2.1.2
Application areas
Subject to change without notice
 Measuring dust emissions in power stations downstream from flue gas desulferization
plants
 Measuring dust in wet purifiers and waste incineration plants
 Measuring dust content in wet exhaust air from technological processes
16
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Product Description
2.2
FWE200DH operating principle
2.2.1
Functional principle
The FWE200DH functions as a bypass system. A partial gas flow is extracted from the flue
gas duct via a sample gas probe, overheated in a thermo cyclone to vaporize water drops
and aerosols and fed to a measuring cell. The sample gas is exposed to a laser beam in the
measuring cell and the scattered light on the particles in the gas flow measured by a
receiver. The measured scattered light intensity serves as basis for determining the dust
concentration. The sample gas is then fed back to the sample gas probe again to be
returned to the duct.
An ejector with a blower creates the gas flow through the measuring system. A partial flow
in the measuring cell serves for cleaning and cooling the optical components.
Fig 1
FWE200DH basic layout
Measuring and control unit
1
Duct
3
2
4
5
6
7
8
9
A D P
S
Sample gas probe
Base plate
S
SOPAS ET operating software
2
Heating band 1
P
Power supply 115 / 230 V AC
3
Heating band 2
A
Output signal 0 ... 20 mA
4
Thermo cyclone
D
Status signals
5
Control unit
6
Measuring sensor with measuring cell
7
Ejector
8
Extraction line
9
Return line
1
Subject to change without notice
Blower unit
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
17
Product Description
2.2.2
Isokinetic behavior
Due to the specific design, the measuring behavior of the FWE200DH does not depend on
changes of the gas velocity in the duct in a wide range. Therefore an isokinetic extraction
(extraction velocity = gas velocity) is not required. It is merely necessary to select the
extraction aperture of the sample gas probe depending on the average velocity (vrated) from
the following Table. In addition, the blower speed (→ p. 30, §2.3.5) is set during startup so
that the flow rate is within the ideal range. This ensures reliable operation even with
changing gas velocities.
The following effects can occur when the flow rate is not adapted to the equipment
conditions:
 Flow rate too low
→ particles can be deposited in the gas-carrying parts.
 Flow rate too high, gas/ambient temperature very low, gas wetness very high
→ the set sample gas temperature is not reached → aerosols/water droplets do not
vaporize completely (heating output of thermo cyclone is limited).
Sample gas probe extraction
aperture
Nominal diameter
DN23
DN18
DN14
Gas velocity in the duct in m/s
vmin
7
10
20
vrated
8.5
15
25
vmax
10
20
30
If vrated is not known when ordering (e.g., no specification in the Technical
questionnaire), the sample gas probe is delivered with standard value DN 18.
2.2.3
Scattered light measuring principle
The FWE200DH works according to the scattered light measurement principle (forward
dispersion). The high sensitivity of this principle makes it particularly suitable for
measuring low particle concentrations.
A laser diode beams the dust particles in the sample gas flow with modulated light in the
visual range (wavelength approx. 650 nm). The light scattered by the particles is recorded
by a highly sensitive measurement receiver, amplified electrically and processed by a
microprocessor in the measuring sensor (“DHSP200”) electronics. The measuring volume
in the gas duct is defined through the intersection of the sender beam sent and the receive
aperture.
Continuous monitoring of the sender output registers the smallest changes in brightness of
the light beam sent which then serve to determine the measurement signal.
Measuring principle
Laser diode
Receiver
Measuring volume
18
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Fig 2
Product Description
Determining the dust concentration
The measured scattered light intensity SI is proportional to dust concentration c. Since the
scattered light intensity not only depends on the number and size of particles but also on
their optical characteristics, the measuring system must be calibrated with a gravimetric
comparison measurement to ensure exact measuring of the dust concentration. The
calibration coefficients determined can be entered directly in the measuring system
(available calibration functions → p. 29, §2.3.4.4, standard factory settings → p. 69, §4.3.1,
input → p. 80, §4.3.9).
2.2.4
Response time
The response time is the time required to attain 90% of the signal peak after a sudden
change in the measurement signal. It can be set anywhere between 1 and 600 s. As the
response time increases, transient measured value fluctuations and interruptions are
damped stronger and stronger which “smoothes out” the output signal.
Fig 3
Response time
Measured
value
in %
100
90% of the signal peak
98
96
Measured value with response time
94
Process change
92
90
88
Response time
86
84
2.2.5
0
10
20
30
40
50
60
70
80
90
t in s
Automatic function check
A function check can be started at fixed intervals as from a definable starting timepoint for
an automatic function control of the measuring system. The setting is made using SOPAS
ET (→ p. 73, §4.3.4). Any unallowed deviations from normal behavior that may occur are
signaled as errors. A function check triggered manually can help localize possible error
causes should a device malfunction occur.
Subject to change without notice
Further information → Service Manual
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
19
Product Description
The function check comprises:
 Approx. 30 s measurement of zero value, control value and contamination of the optical
surfaces
 Every 90 s (standard value), output of values determined (duration parameter can be
modified → p. 73, §4.3.4).
Fig 4
Function check output on a plotter
Contamination degree
(Live Zero = 0%,
20 mA = 40%)
Function check
start
Contamination output
Control value
determination
Control value output
(70%-value, span)
Paper feed
Zero value output (Live Zero)
Function check
end
Zero value measurement
The sender diode is switched off for zero point control so that no signal is received. This
means possible drifts or zero point deviations are detected reliably in the overall system
(e.g., due to an electronic defect). An error signal is generated when the “zero value” is
outside the specified range.
20
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
 The analog output must be activated to output control values on the analog
output (→ p. 73, §4.3.4).
 The last value measured is output on the analog output during control
value determination.
 If the control values are not output on the analog output, the current
measured value is output when control value determination has completed.
 Relay 3 is switched on during a function check (→ p. 42, §3.3.2.1). The single
phases of the function check can be output separately via further digital
outputs (→ p. 29, §2.3.4.4).
 A function check is not started automatically when the measuring system is
in “Maintenance” mode.
 “Function control” is displayed on the LC-Display of the control unit during
the function check.
 If the start timepoint or cycle interval are changed, a function check timed
between parameter setting and new start timepoint is still carried out.
 Changes to the interval time are first effective after the next start
timepoint.
Product Description
Control value measurement (span test)
Sender beam intensity changes between 70 and 100% during control value determination.
The light intensity received is compared against the standard value (70%). The measuring
system generates an error signal for deviations greater than ±2%. The error message is
cleared again when the next function check runs successfully. The control value is
determined with high precision through statistical evaluation of a high number of intensity
changes.
Contamination measurement
To measure contamination, the receiver optics (→ p. 25, Fig. 10) are moved through the
laser beam and the scattered light measured at the same time. The measured value
determined and the value defined as factory setting are used to calculate a correction
factor. This fully compensates any contamination that occurs.
For contamination values < 40 %, a value between Live Zero and 20 mA proportional to the
contamination is output on the analog output
A warning message is output for values > 30 % and a “malfunction” output for values as
from 40 % (the fault current set on the analog output for this case; → p. 69, §4.3.1, → p. 74,
§4.3.5).
Fig 5
Contamination and control value measurement
1
2
3
4
2
1
Laser beam
2
Receiver optics in measuring position
3
Receiver optics in reference position
4
Light conducting cable
3
1
Subject to change without notice
To receiver electronics
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
21
Product Description
2. 3
Device components
2.3.1
Sample gas probe
The sample gas probe serves to extract and return the partial gas flow, It is fixed on a
flange with tube (→ Fig. 7) to be fitted onsite on the gas duct.
The probes are available as standard in two nominal lengths (NL) and materials PVDF (for
gas temperatures < 120 °C) and Hastelloy.
Exchangeable extraction nozzles with nominal diameters DN 14, DN 18 and DN 23 are
supplied for adapting the flow rate (→ p. 18, §2.2.2).
Fig 6
Sample gas probe
1
A
Ø2
2
00
22,5°
3
A
4
1
2
3
4
5
6
5
6
NL
2.3.2
Flange with tube
Fig 7
Flange with tube
Duct wall
Flange with tube
Sample gas probe
Extraction pipe
Extraction nozzle
Return pipe
NL = 600 mm
1200 mm
Flange DIN 2631 ND6, NW 125
(152)
Ø 200
Ø 18
200
If required, the flange with tube can also be supplied with other dimensions and materials.
22
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Ro 139.7 x 4
Material St 37 or
1.4571
Product Description
2.3.3
Extraction and return hoses
Sample gas probe and control unit are connected with flexible hoses with NW32 for gas
extraction and NW 50 for gas return. Standard length is approx. 1.2 m, heating is not
required in most cases (deliverable as option). Longer hoses have a higher maintenance
effort (clearing deposits / caking) and cause higher cooling of the extracted partial gas flow
as well as pressure loss, and are therefore only usable in exceptional cases after checking
the operating conditions.
2.3.4
Measuring and control unit
The measuring and control unit comprises the following components, mounted on a base
plate (7).
 Thermo cyclone (1) for overheating the sample gas with temperature sensor (2) to regulate the sample gas temperature
 Measuring sensor (3) with sender and receiver electronics, and measuring cell to transport the partial gas flow through the optical measuring volume of the sender beam
 Ejector (4) to feed the partial gas flow
 Control unit (5).
Fig 8
Measuring and control unit (without weatherproof cover, with backpurge option and cover at the bottom)
1
2
3
5
6
7
4
8
Subject to change without notice
8
9
10
11
12
13
6
8
9
Adapter for extraction hose (standard)/ to
connect the backpurge unit option
Hinge for weatherproof cover
Backpurge unit option
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
10
11
12
13
Pressure monitoring
Extraction hose
Return hose
Cover at the bottom
23
Product Description
Sample gas flow is monitored with a differential pressure sensor between the thermo
cyclone outlet and measuring cell inlet.
The application-dependent equipment and device parameters can be set using SOPAS ET
(→ p. 68, §4.3 ff). Three independent software modules are available depending on the
function (“FWE200DH” for system functions, “DH SP200” for measuring functions and
“MCU” for input/output functions; → p. 66, §4.2.3.5). The parameters are stored reliably
even in the case of a power failure.
When in operation, the measuring and control unit is covered by a two-piece hood that
serves as weather protection at the same time for outdoor installations. Both parts (2) are
hung on hinges (1) on the base plate, can be swiveled away sideways and locked together
with lock (3).
Fig 9
Weatherproof cover for FWE200DH
1
2
3
2
1
Type code
A type plate identifies the respective version of the measuring and control unit:
Version
Without
Backpurge unit option
With
Without
Heated extraction
hose option
With
Modbus TCP
Optional Interface
Ethernet type 1
module
Profibus DP
24
Type code
FWE200DH-
X
N
B
X
X
N
H
J
E
P
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Parameter
Product Description
2.3.4.1
Thermo cyclone
The thermo cyclone comprises a housing with insulation, a swirl chamber with inlet and
outlet connections and 2 heating bands to overheat the partial gas flow. The inlet
connection is arranged tangential which creates a swirl flow in the swirl chamber. A PTFE
nozzle in the inlet connection accelerates the flow. The swirl chamber can be accessed
easily for inspection and possible cleaning after opening a cover.
Temperature sensors attached to the heating bands measure the temperatures which are
monitored by the microprocessor control in the control unit. Additional built-in temperature
fuses switch the heating bands off at temperatures above approx. 425 °C. This effectively
prevents damage to the thermo cyclone through overheating even during a possible
electronics failure.
A temperature sensor is fitted on the thermo cyclone outlet and serves as encoder for
regulating the sample gas temperature.
2.3.4.2
Measuring sensor
The measuring sensor comprises two modules installed in one stainless steel housing
(p. 25, Fig. 10):
 Electronics unit (1) with the optical and electronic subassemblies to send and receive
laser beam (2) as well as signal processing and evaluation.
 Measuring cell (3) with receiver optics (4), light trap (5) and nozzle to transport the
sample gas flow.
The electronic unit is connected to the control unit with a connection cable for signal
transmission and voltage supply (24 V DC).
Fig 10
Measuring sensor open
2
3
4
5
Subject to change without notice
1
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
25
Product Description
Fig 11
Sample gas and purge air feed
From thermo cyclone (→ page 23, Fig. 8)
1
5
2
Light trap
6
7
4
3
6
7
1
To mixing tube in ejector (→ page 23, Fig. 8)
Subject to change without notice
Sample gas (1) from the thermo cyclone flows down through measuring tube (2) vertically
through laser beam (3). The active measuring volume is within the measuring tube so that
particles of the sample gas flowing through are recorded by the laser beam. The scattered
light signal measured by the receiver therefore represents the dust content in the partial
gas flow.
Clean air is blown into measuring cell (3) through small opening (4) in the measuring tube
and then transported further via measuring openings (6) with the sample gas. The purge
air amount is very low in relation to the sample gas flow so that no mixing with the
measuring volume occurs and the purge air has no effect on measuring behavior.
Condensate that may occur due to condensation effects can flow out through 2 openings
(7) in the nozzle in the sample gas flow (is drawn away by the partial vacuum).
26
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Product Description
2.3.4.3
Control unit
The control unit has the following functions:
 Starting and stopping the FWE200DH
 Temperature control and monitoring for thermo cyclone heating
 Sample gas flow control
 Monitoring and controlling gas feed (switching blower unit on/off)
 Recording and evaluating status signals
 Controlling data traffic and processing data of the measuring sensor connected via the
RS485 interface and system control
 Signal output via analog output (measured value) and relay outputs (device status)
 Signal input via analog and digital inputs
 Power supply for the connected measuring sensor via 24 V switch-mode power supply
with wide range input
 Communication with higher level control systems via optional modules
Apart from the control electronics, the control unit also contains the connection elements
for thermo cyclone, measuring sensor and blower unit, as well as for analog and status
signals.
Measured values and status messages are output on an LC-Display. It also allows
configuring basic functions.
The control unit has a sheet steel housing as standard.
Fig 12
Control unit
1
2
3
4
5
6
Subject to change without notice
7
1
2
3
4
Display module
Fuses
FI circuit breaker
Main switch
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
5
6
7
Processor boards for system control (“FWE200DH”) and
data recording/processing and signal input/output
(“MCU”)
Terminal block for power supply
Interface module
27
Product Description
Standard interfaces
 Analog outputs
3 outputs 0/2/4...22 mA (electrically isolated, active, resolution 10 bits) to output
scattered light intensity (corresponds to uncalibrated dust concentration), calibrated
dust concentration and scaled dust concentration
 Analog inputs
6 inputs 0...20 mA (without electric isolation, resolution 10 bits) to connect external
sensors for measuring gas temperature, gas pressure, gas wetness and O2 content for
calculating scaled dust concentration values
 Relay outputs
9 changeover contacts 48 V, 1 A to output status signals operation/malfunction, maintenance, function check, maintenance request, limit value
 Digital inputs
8 inputs to connect potential-free contacts for starting the function check, setting maintenance mode, purge air monitoring, triggering backpurging (when installed → p. 30,
§2.3.6.1) and activating the second calibration function (option, → p. 31, §2.3.6.3)
 Communication
– USB 1.1 and RS232 (on terminals) for measured value inquiries, setting parameters
and software updates.
– Interface module Modbus TCP for communication with higher-level control system
LC-Display
Functions
 Display measured values and status information
Type
LED
LC-Display
Power (green)
Failure (red)
Maintenance
request (yellow)
Graphic display
(main screen)
Text display
Maintenance request
2 measured values as bars (e.g., dust concentration
or scattered light intensity and sample gas
temperature or differential pressure), selection as
shown on p. 107, § 4.6.4
8 diagnosis values (→ p. 104, Fig. 84)
LC-Display with graphic (left) and text display (center and right) (example)
Subject to change without notice
Fig 13
Display
Power supply OK
Function fault
28
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Product Description
•
Control buttons for basic configuration
Button
Function
 Toggle between text and graphic display
 Display the contrast setting (after 2.5 s)
Select next/previous measured value page
Display alarm or error messages
Display main menu and selection of submenus
Meas
Arrows
Diag
Menu
After the measuring system has been switched on, the start phase of the FWE200DH is
shown on the LC-Display during the warming up time (→ p. 53, §4.1.2).
2.3.4.4
Extended calibration function
The following regression functions to calibrate dust concentration measurement are
implemented in the FWE200DH as standard (→ p. 18, §2.2.3, → p. 80, §4.3.9):
 Polynomial
c = cc2•SL2 + cc1•SL + cc0
 Exponential
c = cc2•e (cc1•SL) + cc0
 Logarithmic
c = cc2•Ln(cc1•SL) + cc0
 Power
c = cc2•SLcc1 +cc0
Two can be used independent of each other (selection and configuration → p. 80, §4.3.9).
Digital input DI5 can be used to toggle between the two calibration functions selected.
Apart from that, single values can be output during the function check (→ p. 19, §2.2.5).
Digital input
DI5
DI6
DI7
DI8
Function
Toggle between calibration function 1 and calibration function 2
Output the last contamination value determined on the analog output
Output the last control value determined on the analog output
Output the last zero value determined on the analog output
Relay output
6
7
8
9
Function
Status signal for output of last contamination value
Status signal for output of last control value
Status signal for output of last zero value
Not used
Subject to change without notice
Optional Interface module
The standard built-in Modbus TCP module can be swapped for an Interface module for
Profibus DP V0 or Ethernet (type 1) (→ p. 139, §7.3.6).
The module is installed on a top hat rail and connected to the “MCU” processor board with
a corresponding cable.
Profibus DP-V0 to transfer via RS485 according to DIN 19245 Part 3 as well
as IEC 61158.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
29
Product Description
2.3.5
Blower unit
The blower unit serves to feed the sample gas into the measuring and control unit via the
ejector. A flexible NW 25 hose serves as connection. The ejector delivers a partial flow into
the measuring cell at the same time to keep the optical components clean.
The blower control with frequency converter regulates the motor speed and therefore the
blower output for ideal sample gas flow.
Fig 14
Blower unit
1
To ejector
2
1
2
3
4
Blower
Hose NW 25
Base plate
Air filter with integrated preliminary
filter
5
Blower control
3
4
5
2.3.6
Options
2.3.6.1
Backpurge unit
Subassembly (→ p. 23, Fig. 8) to backpurge the extraction line (hose and sample gas probe)
comprising:
 Solenoid valve to connect instrument air
 Ball valve in the sampling line to close off the thermo cyclone during the purge process.
Backpurging is started automatically during the function check. In addition, a purge
process can be triggered manually by closing digital input DI4 with an external switch.
The measuring system is in “Maintenance” mode during the purge process. The purge
process is displayed on the LC-Display.
This option is released with a codeword when retrofitted later (included in scope of
delivery).
On request, the backpurge option can also be delivered for connecting water
as purge medium.
30
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
A weatherproof cover is available for use outdoors (→ p. 139, Fig. 107).
Product Description
2.3.6.2
Heated extraction hose
In special single cases (e.g., very low gas temperature and high gas wetness, very low
ambient temperatures, limitation of heater temperatures), it can be useful to heat the
extraction line as well. The standard extraction hose used can be replaced with a readymade hose with heating. The measuring and control unit must then be specially adapted
(type code → p. 23, §2.3.4).
An additional temperature sensor monitors the gas temperature at the thermo cyclone
inlet with this option (Pos. 3 in → p. 23, Fig. 8).
2.3.6.3
Remote unit
Module with LC-Display to display measured values and status, data inquiry and
configuration. A cable to be installed onsite then serves to connect to the system
technology (RS485) in the control unit.
Following wire cross-sections are required depending on the distance to the measuring and
control unit:
Max. cable length in m
120
250
500
1000
Wire cross-section in mm²
0.14
0.25
0.5
1.0
The remote unit can also be delivered with an optional integrated power supply unit for
separate power supply (recommended for longer distances to measuring and control unit).
Remote unit
Subject to change without notice
Fig 15
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
31
Product Description
Cover at the bottom
This subassembly serves as additional protection of the measuring system at low ambient
temperatures. It is installed on the base plate of the measuring and control unit and closes
the weatherproof cover at the bottom.
Fig 16
Cover at the bottom
2.3.6.5
Test equipment for linearity test
A linearity test can serve to check the correct measurement function (see Service Manual).
In this case, filter glasses with defined transmission values are positioned in the beam
path and the values compared against those measured by the measuring system.
Compliance within the allowed tolerance means the measuring system is working correctly.
The filter glasses with holder required for the check are deliverable including a carrying
case.
Subject to change without notice
2.3.6.4
32
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Assembly and Installation
FWE200DH
3
Assembly and Installation
Subject to change without notice
Project planning
Assembly
Installation
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
33
Assembly and Installation
3. 1
Project planning
The following Table provides an overview of the project planning work necessary as
prerequisite for trouble-free assembly and subsequent device functionality. You can use
this Table as a Checklist and check off the completed steps.
Task
Determine the
measuring and
installation
location
for the device
components
Requirements
Inlet and outlet paths
according to DIN EN
13284-1 (inlet at least 5x
hydraulic diameter dh,
outlet at least 3x dh;
distance to stack opening at
least 5x dh)
– Uniform flow distribution
– Representative dust distribution
Sample gas probe
installation position
Accessibility, accident
prevention
Installation free of
vibrations
Ambient conditions
Intake air for blower unit
Select device
components
Plan
calibration
openings
Plan power
supply
Internal duct diameter,
insulation, wall thickness
Gas temperature
Supply voltage, internal
duct pressure
Access
Distances to measuring
level
Operating voltage, power
requirements
For round and square ducts:
dh = duct diameter
For rectangular ducts:
dh = 4x cross-section divided by
circumference
Whenever possible, no deflections,
cross-section variations, feed and drain
lines, flaps or fittings in the area of the
inlet and outlet paths
Installation angle to horizontal 15°;
vertical installation from the top
possible for horizontal or slanted ducts
The device components must be easily
and safely accessible
Acceleration < 1 g
Work step
– Follow specifications for new equipment
– Select best possible location for existing equipment;
– For too short inlet/outlet paths: Inlet
path > outlet path

If conditions cannot be ensured, define
flow profile according to DIN EN 13284-1
and select best possible location
Select best possible location
Provide platforms or pedestals as required
Eliminate/reduce vibrations through
suitable measures
Limit values according to Technical Data If necessary, enclose device components
(→ p. 132, §7.1)
Whenever possible, low amount of dust, Select best possible location for air intake
no oil, moisture or corrosive gases
Determine required purge air hose length
Nominal length and material of sample Select suitable components as described
gas probe
in → p. 132, §7.1
Type of measuring and control unit and
blower unit
Easy and safe
No mutual interference between
calibration probe and FWE200DH
According to Technical Data (→ p. 132,
§7.1)
Provide platforms or pedestals as required
Plan sufficient distance between measuring and calibration level (approx. 500 mm)
Plan adequate cable cross-sections and
fuses
Subject to change without notice
NOTICE:
 Consider the weights of these components when planning brackets and
strength of fitting locations for measuring and control unit and blower unit.
34
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Assembly and Installation
3.2
Assembly
Carry out all assembly work onsite. This includes:
 Fitting the flange with tube
 Installing the measuring and control unit
 Installing the blower unit
WARNING:
 Observe the relevant safety regulations as well as the safety notices in
Section 1 during all assembly work.
 Only carry out assembly work on equipment with hazard potential (hot or
aggressive gases, higher internal duct pressure) when the equipment is at
a standstill.
 Take suitable protection measures against possible local hazards or
hazards arising from the equipment.
3.2.1
Fitting the flange with tube
The flange must be fitted so that any condensate occurring can flow back into the duct (→
Fig. 17). Ensure the sample gas probe is aligned as shown in p. 36, Fig. 18.
Vertical fitting from above is also possible for horizontal or slanted ducts.
Fig 17
Fitting the flange with tube
Duct wall
Fitting from above
Flange with tube
15°
Approx. 20 m
Flange with tube dimensions → p. 22, Fig. 7
Subject to change without notice
If none of the flanges with tube in the scope of delivery (→ p. 134, §7.2.2) should
or could be used (e.g., on GRP ducts), these must be provided onsite under
consideration of the probe dimensions (→ p. 134, Fig. 101 and → p. 134, Fig. 102).
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
35
Assembly and Installation
Fig 18
Sample gas probe alignment
Horizontal duct
Vertical duct
Flow direction
Flow direction
Flow direction
Work to be performed
 Measure the fitting location and mark the installation location.
 Remove insulation (when fitted)
 Cut out suitable aperture in the duct wall; with brick and concrete ducts, drill suitably
sized hole (for flange tube diameter → p. 22, Fig. 7).
NOTICE:
⊗ Do not let separated pieces fall into the duct.
 Insert the flange with tube in the opening and weld it (steel ducts).
 For brick or concrete ducts, weld the flange with pipe onto the anchor
plate when necessary and fasten it on the duct.
 Use junction plates as well on ducts with thin walls.
 Close off the flange opening after fitting to prevent gas escaping.
Installing the measuring and control unit
Consider the following points when selecting the installation location:
 Measuring and control unit (1) must be fitted on a level, vertical base at an easily
accessible, protected location with dimensions according to Fig. 19.
 Maintain the distances to sample gas probe (2).
 The fitting location must be vibration free.
 Ambient temperatures must be within the permissible range (→ p. 132, §7.1), take
possible radiant heat into consideration.
 Suitable hoisting gear and sufficient clearance are required for transporting and fitting
the measuring and control unit (weight → p. 132, §7.1).
36
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
3.2.2
Assembly and Installation
Assembly dimensions
813
1
650
150...20
0
70
286
< 250
Alternative possible position
Recommended
position
100
2
250
Min.
15 °
2
500 ... max. 900
Ø 14
24
30
<100
650
63
722
Fig 19
3
Distance as large as required
for probe installation
Duct wall
3
3 = flange with tube
1
365
Min. 700
Weatherproof cover open
Subject to change without notice
Clearance for Service
Min. 1385
(dimensions in mm)
Work to be performed
 Prepare and fit fastening points according to p. 37, Fig. 19.
 Fit the measuring and control unit.
The measuring and control unit can also be fitted on an optionally deliverable
frame (→ p. 138, Fig. 106)
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
37
Assembly and Installation
3.2.3
Installing the blower unit
Consider the following points when selecting the installation location:
 A level, vertical base at an easily accessible, protected location with clean air when
possible is required.
 The distance to the measuring and control unit must not exceed 10 m. Lay the hose
from the ejector to the measuring and control unit running downwards to the blower
unit (avoids water collecting).
 The intake temperature must be within the permitted range (→ p. 132, §7.1). In unfavorable conditions, lay an air intake hose or pipe to a location with better conditions.
 Provide sufficient clearance to exchange the filter element and to attach and remove
the weatherproof cover when installing outdoors (→ Fig. 20).
 Suitable hoisting gear and sufficient clearance are required for transporting and fitting
the blower unit (weight → p. 132, §7.1).
Fig 20
Blower unit layout and assembly dimensions (dimensions in mm)
Duct
470
(550)
> 140
Clearance to fit weatherproof cover
470
(550)
> 160
Clearance to exchange filter element
Steel pipe 50 x 5
DIN 2391
(dimensions in mm)
Assembly work
 Prepare holder (→ p. 38, Fig. 20).
 Fasten the blower unit with 4 M8 screws.
 Check whether the filter element is fitted in the filter housing otherwise fit when
necessary.
The blower unit can also be fitted on an optionally deliverable frame (→ p. 138,
Fig. 106)
38
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
M8
50
Alternative: Mounting bracket
Assembly and Installation
Weatherproof cover for blower unit
The weatherproof cover (→ p. 139, Fig. 107) comprises a cover and locking set.
Installation:
 Fit the locking pins from the locking set on the base plate.
 Put the weatherproof cover on from above.
 Insert the holding catches into the counterpieces from the side, twist and lock in.
3.2.4
Installing the remote unit option
Install the remote unit in an easily accessible, protected location (→ Fig. 21). Observe the
following points during installation:
 Maintain the ambient temperature according to the Technical Data; take possible
radiant heat into consideration (shield when necessary).
 Protect against direct sunlight.
 Whenever possible, choose an installation location with minimum vibrations; dampen
any vibrations when necessary.
 Leave enough clearance for cables and opening the door.
Assembly dimensions
Fig 21
Remote unit assembly dimensions
M8
320
340
210
> 250
160
Clearance for cables
125
> 350
Clearance to open door
Subject to change without notice
(Dimensions in mm)
The remote unit can be fitted up to 1000 m from the measuring and control unit. We
therefore recommend fitting the remote unit in a control room (measuring station or
similar) to ensure free access. This considerably simplifies communication with the
measuring system in order to set parameters or to locate malfunction or error causes.
It is advantageous to provide weather protection (tin roof or similar), to be made onsite, for
use outdoors.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
39
Assembly and Installation
3. 3
Installation
WARNING:
 Observe the relevant safety regulations as well as the safety notices in
Section 1 during all installation work.
 Take suitable protection measures against possible local hazards or
hazards arising from the equipment.
NOTICE:
 During installation, it must be possible to switch the power supply to the
FWE200DH off using a power isolating switch/circuit breaker in
accordance with EN 61010-1.
 After completion of the work or for test purposes, the power supply may
only be activated again by the personnel who carried out the work and
complying with the valid safety regulations.
3.3.1
General information
Prerequisites
The assembly work described in §3.2 must have been carried out before starting
installation.
For the power supply to the FWE200DH, a one-phase main supply voltage
– 230 V AC 50/60 Hz with fuse min. 10 A or
– 115 V AC 50/60 Hz with fuse min. 15 A
must be available.
NOTICE:
 Only use cables specified for temperatures up to 75°C (EN 61010-1:2011
5.1.8 Connection Boxes of Field Devices).
The control unit can reach a temperature > 60°C due to self-heating at
maximum ambient temperature.
 Plan adequate line cross-sections (→ p. 132, §7.1).
 Before connecting the components, check that the power voltage/
frequency available matches the delivered version of the measuring and
control unit and blower unit.
40
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Installation work
Carry out all installation work onsite unless otherwise explicitly agreed with SICK or
authorized representatives. This work involves:
 Laying power supply and signal cables.
 Installing switches and mains fuses.
 Connecting the blower unit to the corresponding terminals in the control unit of the
measuring and control unit.
 Connecting the cables for analog and status signals as well as digital inputs to the
terminals of the I/O board in the control unit.
 Connecting the measuring and control unit to the main supply voltage.
Assembly and Installation
3.3.2
Connecting the control unit
 Check that changeover switches (1) for heater voltage are set to the supply voltage
available at the installation location and, if not, set as required.
Fig 22
Switch for supply voltage in the measuring and control unit
1
Fig 23
Control unit connections
1
11
10
2
3
4
5
Subject to change without notice
9
8
1 Connection for Display module
2 Processor board for data recording/processing
and signal input/output (MCU)
3 USB plug connector
4 Connections for measuring sensor (DHSP200)
5 Connections for system control processor board
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
7
6
7
8
9
10
11
6
System control processor board (FWE200DH)
Connections for signal inputs and outputs
Connections for blower control cable
Connections for backpurge option
Connection for external temperature sensors
Connection for remote unit
41
Assembly and Installation
3.3.2.1
Connecting cables for digital, analog and status signals
 Connect outputs for digital, analog and status signals using suitable cables (e.g., LiYCY
4x2x0.5 mm²) according to Fig. 24 and the following Table.
Fig 24
Connections for processor boards
1
2
3
4
5
6
7
8
9
10
1
14
13
12
11
Connection for cable shielding
Supply voltage 24 V DC
RS232
Connection for analog output AO1
Connections for analog inputs AI1 and AI2
Processor board for data recording/processing
and signal input/output (MCU)
7 System control processor board (FWE200DH)
8 Connections for measuring sensor (DHSP200)
(connected at the factory)
1
9 Connections for system control processor board
(FWE200DH) (connected at the factory)
10 Connections for analog inputs AI3 to AI6
11 Connections for relays 6 to 9 (with the extended
calibration function option installed) → p. 31,
§2.3.6.3)
12 Connections for digital inputs D15 to D18 (with
the extended calibration function option installed)
→ p. 31, §2.3.6.3)
13 Connections for analog outputs AO2 and AO3
14 Connections for relays 1 to 5
15 Connections for digital inputs DI1 to DI4
Subject to change without notice
1
2
3
4
5
6
15
42
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Assembly and Installation
Connections on processor board for data recording/processing and signal input/
output (MCU)
Subject to change without notice
Terminal No. Connection Function
1
COM
Output relay 1 (operation/malfunction)
2
n.c.1)
3
n.o.2)
4
COM
Output relay 2 (maintenance)
1)
5
n.c.
6
n.o.2)
7
COM
Output relay 3 (function check)
8
n.c.1)
9
n.o.2)
10
COM
Output relay 4 (maintenance request)
11
n.c.1)
12
n.o.2)
13
COM
Output relay 5 (limit value)
14
n.c.1)
15
n.o.2)
16
d in1
Digital input DI1 (start function check)
17
d in2
Digital input DI2 (set maintenance mode)
18
gnd
Ground for DI1 and DI2 (usable as shield connection for signal cable)
19
d in3
Digital input DI3 (purge air monitoring)
20
d in4
Digital input DI4 (triggering backpurge option when installed)
21
gnd
Ground for DI3 and DI4 (usable as shield connection for signal cable)
22
+
Analog output AO1
23
24
gnd
25
a in1
Analog input AI1
26
gnd
27
a in2
Analog input AI2
28
gnd
1): Closed when without current (normal closed)
2): Open when without current (normal open)
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
43
Assembly and Installation
Terminal No. Connection Function
51
d in5
Digital input DI5 (calibration function switchover)
52
d in6
Digital input DI6 (output contamination value on AO)
53
gnd
Ground for DI5 and DI6
54
d in7
Digital input DI7 (output control value on AO)
55
d in8
Digital input DI8 (output zero value on AO)
56
gnd
Ground for DI7 and DI8 (usable as shield connection for signal cable)
57
COM
Output relay 6 for output of last contamination value
58
n.c.1)
59
n.o.2)
60
COM
Output relay 7 for output of last control value
1)
61
n.c.
62
n.o.2)
63
COM
Output relay 8 for output of last zero value
64
n.c.1)
65
n.o.2)
66
COM
Not used
67
n.c.1)
68
n.o.2)
71
+
Analog output AO2
72
73
gnd
Ground (usable as shield connection for signal cable)
74
+
Analog output AO3
75
76
gnd
Ground (usable as shield connection for signal cable)
77
+
Analog input AI3
78
79
gnd
Ground for AI3 and AI4 (usable as shield connection for signal cable)
80
+
Analog input AI4
81
82
+
Analog input AI5
83
84
gnd
Ground for AI5 and AI6 (usable as shield connection for signal cable)
85
+
Analog input AI6
86
87
+
24 V DC for external power supply (max. approx. 500 mA)
88
1): Closed when without current (normal closed)
2): Open when without current (normal open)
44
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Connections on processor board for system control (FWE200DH)
Assembly and Installation
3.3.2.2
Fig 25
Connecting the blower unit and supply voltage
 Check that changeover switch (1) for power supply is set to the supply voltage available
at the installation location and, if not, set as required.
Switch for supply voltage in the blower unit
Subject to change without notice
1
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
45
Assembly and Installation
Fig 26
Connecting the blower unit and supply voltage
11
12
10
7
4
6
9
8
2
1
5
3
 Connect the mains cable of blower unit (1) to corresponding terminals (2) in the control
unit.
 Unscrew nut (3) from the PG screw fitting (belongs to control cable).
 Push plug-in connector (4) with control cable (5) through the opening in the control unit
(closed in Fig. 26 through PG screw fitting (6)), insert the PG screw fitting through the
opening and screw together with the nut and plug the plug-in connector on connection
(7) on the processor board.
 Connect the suitable 3-wire mains cable (3) with sufficient cross-section from the
onsite power supply to the corresponding terminals (9) in the control unit.
 Close off unused cable openings with dummy plugs.
3.3.3
Fitting and connecting the Interface module option
 Loosen the fuse for ribbon cable (10) (→ Fig. 26) on top hat rail (11) and plug the plug-in
connector of ribbon cable (12) on the Interface module (→ p. 139, §7.3.4).
 Push the onsite network cable through a free PG screw fitting, connect to the Interface
module and plug the Interface module onto the top hat rail.
46
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
WARNING:
 Be sure to check the wiring before switching the supply voltage on.
 Only modify wiring when disconnected from the power supply and potentialfree.
Assembly and Installation
Installing the backpurge option (only necessary when ordered separately)
3.3.4
Fit the backpurge subassembly onto the measuring and control unit
 Disconnect extraction hose (1) from connection of adapter (2), take the adapter off and
loosen connection cable (3) to the control unit from measuring sensor (4).
 Loosen top fastening nut (5) and remove lower nut (6), position backpurge subassembly (7) on the bolts on the base plate and fasten with the nuts.
The SW13 jaw wrench (9) located behind the flap of thermo cyclone (8) can
be used to loosen/tighten the nuts.
 Fasten pressure monitor (10) on the base plate and connect onsite compressed air
hose (11) to the pressure sensor.
 Connect hose piece (12) from the ball valve to the connection of adapter (2) and attach
the adapter on thermo cyclone (13) again.
 Connect extraction hose (1) to connection (14) of the backpurge subassembly.
 Connect connection cable (3) to the control unit on measuring sensor (4) again.
Fitting the backpurge subassembly onto the measuring and control unit
Fig 27
8
9
3
1
2
4
13
7
5
6
10
Subject to change without notice
12
14
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11
47
Assembly and Installation
Connect the backpurge option
 Loosen the wires of connection cable (1) on plug-in connector (2), pull the cable
through one of the rear PG screw fittings (3) and connect the wires, color correct, to the
plug-in connector again.
 Plug the plug-in connector onto the system control processor board (4) and cable shoe
(5) on with separator bolt (6).
 Switch actuation switch (7) to the upper position.
Fig 28
Connecting the backpurge option
2
1
3
2
6
4
5
Subject to change without notice
7
48
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Assembly and Installation
3.3.5
Connecting the remote unit option
Version without power supply unit
 Connect the connection cable to the measuring and control unit (4-wire, twisted pair,
with shield) to the connections in the control unit (→ p. 41, Fig. 23) and the module of the
remote unit.
Fig 29
Connections in the remote unit (version with integrated wide-range power pack)
+24 V
-24 V
Shield
RS485 A
RS485B
Connection cable to
measuring and
control unit
AC power cable
Subject to change without notice
Version with integrated wide-range power pack:
 Connect the 2-wire cable (twisted pair, with shield) to the connections for RS485 A/B
and shield in the control and remote unit.
 Connect the 3-wire mains cable with sufficient cross-section to the onsite power supply
and the corresponding terminals in the remote unit.
NOTICE:
 During installation, it must be possible to switch the power supply off
using a power isolating switch/circuit breaker in accordance with
EN 61010-1.
 After completion of the work or for test purposes, the power supply may
only be activated again by the personnel who carried out the work and
complying with the valid safety regulations.
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49
Subject to change without notice
Assembly and Installation
50
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Start-up and Configuration
FWE200DH
4
Start-up and Configuration
Subject to change without notice
Putting the FWE200DH into operation
Basics
Setting standard parameters
Setting the Interface module parameters
Activating the backpurge option
Operating/setting parameters via the LC-Display
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51
Start-up and Configuration
Putting the FWE200DH into operation
4. 1
Prerequisite for carrying out the activities described in the following is completion of the
assembly and installation of the measuring and control unit and blower unit as described
in Section 3.
Preparatory work
4.1.1
 Check that measuring sensor (1) is in the measuring position (safety lever (2) must be
in the upper position, → Fig. 30) and is locked.
 Push the NW 25 flexible hose (3) (belongs to the blower unit) onto the connection on
ejector (4) and secure with a hose clip.
 Push the NW 50 hose (5) for gas return (scope of delivery) over the connections on the
ejector and sample gas probe and secure with hose clips.
 Connect the NW 32 hose (6) for gas extraction to the connections of the thermo cyclone
and sample gas probe.
 Open the door of the control cabinet door of the measuring and control unit and check
that all fuses (7) are switched on (if not, switch on).
Fig 30
Measuring and control unit
6
1
4
5
3
2
 Check that the switchover for the heater voltage (→ p. 41, Fig. 22) and power supply of
the blower unit (→ p. 45, Fig. 25) are set to the supply voltage available at the installation
location; if not, switch accordingly.
 Switch the main switch on.
52
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Subject to change without notice
7
Start-up and Configuration
4.1.2
Starting the FWE200DH
The start phase of the FWE200DH starts when the main supply voltage is switched on.
The start process runs as follows:
Function
Marginal conditions
Switch main supply voltage on
↓
Heating bands 1 and 2 of the thermo
cyclone are heated up
↓
•
Blower unit is switched on automatically
•
When average value of heat band temperatures
“Heat1” and “Heat2” ≥ Tnominal + warning
threshold
or “Heat1” or “Heat2” ≥ 200 °C
↓
End of start phase
•
•
When sample gas temperature “T_Gas2” = T
nominal
When switching to maintenance mode
Subject to change without notice
The current measured values are displayed on the LC-Display of the control unit (→ p. 28,
Fig. 13, → p. 107, §4.6.4.) The start phase is signaled with “Initialization” instead of
“Operation”.
Relay 4 (maintenance) is active during the start phase. Any malfunctions possibly present
are not reported to relay 1 (operation/malfunction) during this time.
The start phase finishes when the sample gas temperature reaches the set nominal value
for the first time (average duration approx. 30 min). If this value is not reached (e.g., due to
gas wetness too high/gas temperature too low in duct), error “Heating up phase” is
displayed on the LC-Display after 1 hour.
After the start phase has finished, warnings and malfunction messages are displayed on
the LC-Display (apart from when the sample gas temperature exceeds the tolerance range
[standard value for warning = Tnominal - 10 K; standard value for malfunction = Tnominal
± 30 K]) and output on relay 1.
The blower unit is switched off when:
– The gas temperature sinks below the malfunction threshold value
– The average value of the temperatures from heating bands 1 and 2 sinks below 80°C
– For certain device malfunctions (see Service Manual for details).
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53
Start-up and Configuration
4.1.3
Fitting the sample gas probe
WARNING: Danger from exhaust gas
 Only fit the sample gas probe on equipment with hazard potential (hot or
aggressive gases, higher internal duct pressure) when the equipment is at
a standstill.
 Take suitable protection measures against possible local hazards or
hazards arising from the equipment.
 Check that the suitable suction nozzle according to Table p. 18, § 2.2.2 is screwed onto
the extraction pipe; if not, correct accordingly.
 Insert the sample gas probe in the flange with tube according to Fig. 31 and fasten. The
extraction opening of the probe must point in flow direction.
Fig 31
Sample gas probe alignment
Horizontal duct
Vertical duct
Flow direction
Subject to change without notice
Flow direction
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Start-up and Configuration
4.2
Basics
4.2.1
General information
Prerequisite for work described in the following is completion of the assembly and
installation as described in Section 3.
Start-up and parameter setting comprise:
 Fitting and connecting the sender/receiver unit,
 Customizing parameter settings according to the respective requirements.
To achieve exact measurement, the measuring system must first be calibrated using a
gravimetric comparison measurement (→ p. 68, §4.3) before being used for continuous
measurement of dust content.
The operating and parameter program SOPAS ET is provided to set the parameters. The
Menu structure simplifies changing settings. Further functions are also available (e.g., data
storage, graphic displays).
4.2.2
Installing the operating and parameter program SOPAS ET
Administrator rights are required to install software.
Prerequisites
 Laptop/PC with:
– Processor: Pentium III (or comparable type)
– USB interface (alternative - RS232 via adapter)
– Working memory (RAM): At least 512 MB
– Operating system: MS-Windows 2000/XP/Vista, Windows 7 (not Windows 95/98/
NT)
 USB interface cable to connect the laptop/PC to the measuring system (control unit).
 The operating and parameter program as well as the USB driver (scope of delivery)
must be installed on the laptop/PC.
 The power supply must be switched on.
Start the file “setup.exe” when the start screen does not appear.
Subject to change without notice
Install the SOPAS ET program
Insert the delivered CD in the PC drive, select the language, select “Software” and follow
the instructions.
Install the USB driver
A special software driver is required for communication between SOPAS ET and the
measuring system via the USB interface. Connect the measuring system to the supply
voltage and to the PC via USB connector to install the driver on the laptop/PC. A message
appears on the display that new hardware has been detected. Now insert the delivered CD
in the PC drive and follow the installation instructions (→ p. 56, Fig. 32).
The driver can also be installed using the hardware installation program in the Windows
Control Panel.
The USB driver creates a new COM port to be used for connecting SOPAS ET to
the device (→ p. 58, §4.2.3.2).
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55
Start-up and Configuration
Installing the USB driver
Subject to change without notice
Fig 32
56
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Start-up and Configuration
4.2.3
Connecting the device
4.2.3.1
Basic settings
 Connect the USB cable to the control unit (→ p. 41, Fig. 23) and the laptop/PC.
 Start “SOPAS ET” and click “Create a new project”.
Fig 33
Start dialog
The following start menu appears.
Fig 34
Start menu
Subject to change without notice
 If required, set the desired language in menu “Tools / Language” (→ p. 58, Fig. 35; only
German and English available at present), confirm with “OK” and restart the program.
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57
Start-up and Configuration
Fig 35
4.2.3.2
Changing the language setting
Configuring the interface
Subject to change without notice
In order to keep the connection setup as short as possible, we recommend
deactivating communication channels not used or required (IP communication,
standard protocol or USB) → p. 59, Fig. 36) .
58
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Start-up and Configuration
COM port
 Click the “Network configuration” button in the Start menu (→ p. 57, Fig. 34) and select
“Standard Protocol”.
 Select the interface that appears after connection of control unit and laptop/PC in the
“Select COM Ports” group, click “Advanced” and configure according to Fig. 36 (settings
are only required during the first connection to the measuring system).
COM port selection and configuration (COM port number depends on the laptop/PC)
Subject to change without notice
Fig 36
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59
Start-up and Configuration
Ethernet
The Ethernet interface module (→ p. 139, §7.3.6) must be installed in the
control unit (→ p. 46, §3.3.3) and configured (→ p. 98, §4.4.2.2) to connect to the
measuring system via Ethernet.
 Click “Network Configuration” in the start menu (→ p. 57, Fig. 34) and select “Internet Protocol
(IP)”.
 Click “Add”, enter the IP address and confirm with “OK”.
Ethernet interface selection (example settings)
Subject to change without notice
Fig 37
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Start-up and Configuration
 Click “Advanced” and configure the interface according to Fig. 38.
Ethernet interface configuration
Subject to change without notice
Fig 38
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61
Start-up and Configuration
4.2.3.3
Fig 39
Connecting using the “Network Scan Assistant” tab
 Click “Network Scan” in the “Network Scan Assistant” tab.
Search for connected devices (COM port number depends on the laptop/PC)
Connection via COM port
Connection via Ethernet (addresses are system-dependent)
Problems on connections via Ethernet can be due to incorrect addressing →
Contact your system administrator.
 Confirm search for connected devices with “OK”.
62
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Subject to change without notice
The following message appears when no device is found (Troubleshooting, see
Service Manual):
Start-up and Configuration
4.2.3.4
Fig 40
Connecting using the “Connection Wizard” menu (valid as from SOPAS ET Version
02.32)
 Select menu “Connection Wizard” and activate selection “Show all connected devices”.
“Communication / Connection Wizard” menu
 Click “Next” and select the interface (“Standard Protocol” for connection via COM port,
“Internet Protocol (IP)” for connection via Ethernet).
Subject to change without notice
Fig 41
Interface selection (shown for IP communication)
 Check the interface configuration for settings according to p. 58, § 4.2.3.2 and change
accordingly if necessary.
 Click “Next”.
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63
Start-up and Configuration
Fig 42
Search for connected devices
Connection via COM port (interface name “Standard protocol”, → p. 63, Fig. 41)
Subject to change without notice
Connection via Ethernet
64
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Start-up and Configuration
The following message appears when no device is found (Troubleshooting, see Service
Manual):
Connection error
Subject to change without notice
Fig 43
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65
Start-up and Configuration
4.2.3.5
Select device
Connection via COM port / Ethernet
Select the required device file in the “Network Scan Assistant / Detected devices” tab and
move it to the “Project Tree” window (drag-and-drop per mouse or click “Add”).
Fig 44
Select device file (example)
Connecting via “Connection Wizard”
Activate the checkbox of the required device file in the “Connection Wizard / Found
devices” (→ p. 64, Fig. 42) and click “Next >”. This transfers the device file to the “Project
tree” window.
Select device file (example)
Subject to change without notice
Fig 45
66
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Start-up and Configuration
4.2.4
Online help
The individual menus and setting options are described in detail in the online help and are
therefore not described further here.
Fig 46
Online help
Subject to change without notice
The installed version is displayed.
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Start-up and Configuration
4. 3
Setting standard parameters
Password
Certain device functions are first accessible after a password has been entered (→ Fig. 47).
Access rights are assigned in 4 levels:
User level
0 “Operator”
1 “Authorized Operator”
2 “Authority”
3 “Service”
Access to
Displays measured values and system states
Displays, inquiries and parameters required for start-up or adjustment to
customer-specific demands and diagnosis
Displays, inquiries as well as all parameters required for service tasks
(e.g., diagnosis and clearance of possible malfunctions)
The level 1 password is contained in the Annex.
The level 1 password is contained in the Annex.
Password entry and language selection
Subject to change without notice
Fig 47
68
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Start-up and Configuration
4.3.1
Factory settings
Parameter
Sample gas
temperature
Nominal value
Value for warning
Value for malfunction
Differential pressure (flow monitoring)
Function check
Analog output (AO)
Live zero (LZ)
Upper measuring range value
(MBE)
Current during maintenance
Current by malfunction
Response time
Measured variable
Output on AO
Dust concentration
1
Scattered light intensity
2
Regression function 1
Coefficients set (only for dust concentration)
Regression function 2
Coefficients set (only for dust concentration)
Value
160°C
< 150 °C and > 180 °C
130°C
0.8 hPa
Every 8 h; output of control values (every 90 s) on
standard analog output
4 mA
20 mA
0.5 mA
21 mA (optional 1 mA)
60 s for all measured variables
Value at LZ
Value at MBE
0 mg/m³
200 mg/m³
0
200
Function type polynomial
0.00 / 1.00 / 0.00
Function type polynomial
0.00 / 1.00 / 0.00
Subject to change without notice
The steps required to modify these settings are described in the following Sections.
Prerequisite: The device data are located in the “Project Tree” window, the level 1 password
has been entered and “Maintenance” mode set.
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69
Start-up and Configuration
4.3.2
Setting “Maintenance” mode
 In the respective device file, switch to directory “Maintenance/Maintenance”, activate
the checkbox in the “Maintenance on/off” and click “Set State” to confirm.
Fig 48
Setting “Maintenance” mode (example for MCU)
Subject to change without notice
“Maintenance” mode can also be set using the buttons on the LC-Display of
the control unit (→ p. 104, §4.6.2) or by connecting an external maintenance
switch to the terminals for Dig In2 (17, 18) in the control unit → p. 41, §3.3.2).
70
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Start-up and Configuration
4.3.3
Changing function parameters
Subject to change without notice
Select device file “FWE200DH” to change temperature and pressure settings and switch to
directory “Configuration / Application Parameter”.
Fig 49
Changing function parameters (example)
4.3.3.1
Change temperature settings
In certain cases, it can be necessary to change the nominal value for sample gas
temperature (e.g., for acid dew point temperature > 160 °C) and/or heater
temperature(s)). To do this, enter the desired values in the respective windows in the group
“Temperature settings” (→ p. 71, Fig. 49).
4.3.3.2
Define limit value for the flow rate
The differential pressure measured between the thermo cyclone and measuring cell can be
used for flow monitoring. Entering a limit value triggers a message when underflown. This
can serve to prevent the flow (e.g., due to deposits in the gas path) from sinking below the
value required for normal device operation by initiating maintenance measures in good
time.
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Start-up and Configuration
The FWE200DH outputs the following messages:
Message
Warning
Monitoring value
Signals
Differential pressure measured
• “Warning Eductor air/flow” displayed on LC-Display
less than 1.5 times the limit
• “Warning” relay triggers
value (generated deviceinternal)
• “Malfunction Eductor air/flow” displayed on LC-DisMalfunction Differential pressure measured
play
less than limit value
• Relay “Malfunction” triggers
 The flow is not monitored when the blower is not in operation, i.e., there are
no warning or malfunction messages.
 Monitoring is active during the start phase (until the sample gas has
reached the nominal temperature or max. 1 hour after the start) when a
limit value has been entered. When the flow is too low, this is only displayed
on the LC-Display. The warning or malfunction relays do not trigger because
the maintenance relay is still active during the start phase.
 The hysteresis for the limit value is 10 %.
For setting, enter a value in window “Limit pGas” in group “Flow settings” (→ p. 71, Fig. 49)
corresponding to approx. 33% of the differential pressure shown on the LC-Display after
flow adjustment according to p. 55, § 4.2. The gas path must be free from deposits in this
case.
Recommendation
– Average differential pressure 1.5 - 2.0 hPa:
Limit value 0.7 hPa
– Average differential pressure 2.0 - 2.5 hPa:
Limit value 0.8 hPa
– Average differential pressure 2.5 - 3.0 hPa:
Limit value 0.9 hPa
4.3.3.3
Set the suction
The following steps are necessary to adapt the suction to the equipment conditions:
 Check the gas path for deposits, clean when necessary.
 Set the frequency in group “Flow setting” (→ p. 71, Fig. 49) using the slider so that the
value displayed in window “Flow” is within the recommended range.
Subject to change without notice
The flow can be set to the lower value of the recommended range for very low
gas temperatures and/or high gas wetness and/or low ambient temperatures.
72
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Start-up and Configuration
4.3.4
Setting the function check
To change the values set at the factory (→ p. 69, §4.3.1), select device file “MCU” and switch
to directory “Adjustment / Function Check - Automatic”. The interval time, control value
output on the analog output and the start timepoint for automatic function check can be
changed here.
Fig 50
“Adjustment / Function Check - Automatic” directory (example for settings)
Entry field
Output duration of
function control
value
Function check
interval
Function Check
Start Time
Parameter
Value in seconds
Remark
Output duration of control values.
Time between two
check cycles
Hours
Minutes
→ p. 19, §2.2.5
Defining a start timepoint in hours and minutes.
Subject to change without notice
The last value measured is output during control value determination (→ p. 20,
Fig. 4).
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73
Start-up and Configuration
4.3.5
Setting the analog output parameters
Select the “Configuration / IO Configuration / Output Parameters” directory to set the
analog outputs.
 Default values → p. 69, §4.3.1
 In order to output the dust concentration under standard conditions
(“Conc. s.c.” (SL)), set the parameters for the analog outputs according to
§4.3.6.
“Configuration / IO Configuration / Output Parameters” directory
Subject to change without notice
Fig 51
74
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Start-up and Configuration
Field
Analog
Outputs
- General
Configuration
Analog
Output 1
Parameter
Parameter
Yes
No
Error Current
Value < Live Zero (LZ)
or > 20 mA
Current in
User value
maintenance
Last value measured
Measured value output
Maintenance
Whenever possible,
current
value ≠ LZ
Value on analog Conc. a.c. (SL)
output 1
Output Error
current
Conc.s.c.dry O2 corr.
(SL)
Live zero
Output
checkcycle
results on the
AO
Write absolute
value
Analog
Output 1
Scaling
Range low
Range high
Limiting Value Limit value
Switch at
Subject to change without notice
Dust concentration under operating
(actual) conditions (based on
scattered light intensity)
Dust concentration under standard
conditions (based on scattered light
intensity)
The selected measured
variables are output on the
analog output.
SL
Scattered light intensity
T _Heater 1
Temperature heater 1
T _Heater 2
Temperature heater 2
T _Heater 3
Temperature heater 3
T _Heater 4
Temperature heater 4
T_Gas2
Sample gas temperature
Select 2 or 4 mA to ensure being able to differentiate between
measured value and switched off device or interrupted current loop.
Control values (→ p. 19, §2.2.5) are not output on the analog output .
Control values are output on the analog output .
Zero point
(0, 2 or 4 mA)
Inactive
Active
Inactive
Active
Lower measuring
range limit
Upper measuring
range limit
Conc. a.c. (SL)
Conc.s.c.dry O2 corr.
(SL)
Hysteresis
type
Remark
Error current is output.
Error current is not output.
mA value to be output in “Malfunction” state (error case) (size
depends on connected evaluation system).
A value to be defined is output during “Maintenance”
The value measured last is output during “Maintenance”
The current measured value is output during “Maintenance”.
mA value to be output in “Maintenance” state
Positive and negative measured values are differentiated.
The amount of the measured value is output.
Physical value at live zero
Physical value at 20 mA
Dust concentration under operating
(actual) conditions (based on
scattered light intensity)
Dust concentration under standard
conditions (based on scattered light
intensity)
Select the measured variable
for which a limit value is to be
monitored.
SL
Scattered light intensity
T _Heater 1
Temperature heater 1
T _Heater 2
Temperature heater 2
T _Heater 3
Temperature heater 3
T _Heater 4
Temperature heater 4
T_Gas2
Sample gas temperature
Assignment of the value entered in the “Hysteris Value” field as
relative or absolute value of defined limit value
Percent
Absolute
Over Limit
Underflow
Define the switching direction
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75
Start-up and Configuration
Field
Limit Switch
Parameters
Limit value
Parameter
Value
Hysteresis
Value
Remark
The limit value relay switches when the entered value is exceeded or
underflown.
Define a tolerance for resetting the limit value relay
Subject to change without notice
Set the parameters for “Analog Output 2(3) Parameter” and “Analog Output
2(3) Scaling” in the same manner as for “Parameter Analog Output 1” and
“Analog Output 1 Scaling”.
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Start-up and Configuration
4.3.6
Setting the analog input parameters
Select the “Configuration / IO Configuration / Input Parameters” directory to set the analog
inputs.
Fig 52
“Configuration / I/O Configuration / Input Parameters” directory
Field
Parameter
Temperature Constant Value
Source
Analog Input 1
Pressure
Source
Constant Value
Analog Input 2
Moisture
Source
Constant Value
Subject to change without notice
Analog Input 3
Oxygen
Source
Constant Value
Analog Input 4
Remark
A fixed value is used to calculate the scaled value.
This parameter opens the “Temperature Constant” field to enter the scaling value in °C or K.
The value from an external sensor connected to analog input 1 (standard scope of delivery) is
used to calculate the scaled value.
This parameter opens the “Analog input 1 - Temperature” field to set the lower and upper
range limit values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Temperature” field to enter the scaling value in mbar (=
hPa).
The value from an external sensor connected to analog input 2 (standard scope of delivery) is
used to calculate the scaled value.
This parameter opens the “Analog input 2 - Pressure” field to set the lower and upper range
limit values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Moisture” field to enter the scaling value in %.
The value from an external sensor connected to analog input 3 (optional module required) is
used to calculate the scaled value.
This parameter opens the “Analog input 3 - Moisture” field to set the lower and upper range
limit values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Oxygen” field to enter the scaling value in %.
The value from an external sensor connected to analog input 4 (optional module required) is
used to calculate the scaled value.
This parameter opens the “Analog input 4 - Oxygen” field to set the lower and upper range
limit values and the Live Zero value.
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Start-up and Configuration
4.3.7
Setting the response time
Select the “Configuration / Value Damping” directory to set the damping time.
Fig 53
“Configuration / Value Damping” directory
Remark
Response time for the selected measured variable ( → p. 19, §2.2.4)
Setting range 1 ... 600 s
Subject to change without notice
Field
Parameter
Damping time Value in s
for Sensor 1
78
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Start-up and Configuration
4.3.8
Defining regression coefficients
To change the values set at the factory (→ p. 69, §4.3.1), select device file “DH SP200” and
switch to directory “Configuration / Application Parameters”.
Fig 54
“Configuration / Application Parameter” directory
Subject to change without notice
Two different functions, independent of each other, can be selected and configured in the
windows “Calibration coefficients for calculation of concentration with scattered light” for
calibrating dust concentration measurement (→ p. 80, §4.3.9).
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79
Start-up and Configuration
4.3.9
Calibration for dust concentration measurement
NOTICE:
 The steps described here serve to avoid input errors. Carrying out
comparison measurements demands special knowledge that cannot be
described in detail here.
 The calculation of regression coefficients cc2, cc1 and cc0 from
coefficients K2, K1 and K0 are only valid for the polynomial function.
The coefficients for other function types (extended calibration function
option) must be calculated separately.
For exact dust concentration measurement, the relation between the primary measured
variable scattered light intensity and the actual dust concentration in the duct must be
established. To do this, the dust concentration must be determined based on a gravimetric
comparison measurement in accordance with DIN EN 13284-1 and set in relation to the
scattered light values measured at the same time by the measuring system.
Steps to be carried out
 Select device file “MCU”, enter the level 1 password (→ p. 68, §4.3) and set the measuring system to “Maintenance” mode (→ p. 70, §4.3.2).
 Select the “Configuration / IO Configuration / Output Parameter” directory (→ p. 74,
Fig. 51) and assign the “Scattered light intensity” measured variable to one of the three
analog outputs available.
 Estimate the measuring range required for the dust concentration in operational state
and enter this in the “Analog output 1 (2/3) Scaling” field assigned to the selected
analog output assigned to the scattered light intensity.
 Deactivate “Maintenance” mode.
 Carry out the gravimetric comparison measurement in accordance with
DIN EN 13284-1.
 Determine regression coefficients from the mA values of the analog output for
“Scattered light intensity” and the actual dust concentrations measured gravimetrically.
2
(1)
c = K2 ⋅ I out + K1 ⋅ I out + K0
Dust concentration in mg/m³
Regression coefficients of the function c = f (Iout )
Current output value in mA
20mA – LZ
I out = LZ + SL ⋅ ----------------------------MBE
SL:
LZ:
MBE:
80
(2)
Measured scattered light intensity
Live Zero
Defined upper range limit value (value entered for 20 mA;
normally 2.5 x fixed limit value)
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
c:
K2, K1, K0:
Iout:
Start-up and Configuration
 Enter the regression coefficients
There are two options:
– Direct input of K2, K1, K0 in a measured value computer.
NOTICE:
In this case, the regression coefficients set in the sender/receiver unit
and the measuring range set in the MCU may not be changed anymore.
On the optional LC Display (when used), the dust concentration is
displayed as uncalibrated value in mg/m³.
– Use of the regression function of the measuring system (use without measured
value computer).
In this case, the correlation to the scattered light intensity has to be determined. To
do this, calculate the regression coefficients cc2, cc1, cc0 to be entered in the
measuring system from K2, K1, K0.
2
c = cc2 ⋅ SL + cc1 ⋅ SL + cc0
(3)
Using (2) in (1), the result is:
20mA – LZ 2
20mA – LZ
c = K2 ⋅  LZ + SL ⋅ ----------------------------- + K1 ⋅  LZ + SL ⋅ ----------------------------- + K0


MBE 
MBE 
Using (3), the result is:
2
cc0 = K2 ⋅ LZ + K1 ⋅ LZ + K0
20mA – LZ
cc1 = ( 2 ⋅ K2 ⋅ LZ + K1 ) ⋅  -----------------------------
MBE
20mA – LZ
cc2 = K2 ⋅  -----------------------------
 MBE 
2
Now enter the regression coefficients cc2, cc1 and cc0 determined in directory
“Configuration/Application parameters” (→ p. 79, Fig. 54→ p. 80, Fig. 4.3.9) (set
sender/receiver unit to “Maintenance” state and enter the level 1 password; reset
the sender/receiver unit back to “Measurement” state afterwards).
Subject to change without notice
This method allows changing the parameters for the selected measuring
range as desired.
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Start-up and Configuration
4.3.10
Data backup
All parameters relevant for recording, processing and input/output of measured values as
well as current measured values can be saved and printed. This allows easy reentering of
set device parameters as needed or registering device data and states for diagnostic
purposes.
The following options are available:
 Saving as a project
Not only device parameters but also data logs can be saved.
 Saving as a device file
Saved parameters can be processed without a device connected and transferred to the
device again later.
See the Service Manual for a description.
 Saving as a protocol
Device data and parameters are registered in the Parameter protocol.
A Diagnosis protocol can be created for analysis of the device function and recognition
of possible malfunctions.
Saving as a project
It is recommended to store a “project” for frequent connections. It is then only necessary to
open this “project” to connect to the device. All data saved beforehand are then transferred
automatically to SOPAS ET.
To save, select the “Project / Export Device” menu and then define the target directory and
file name. The name of the file to be stored can be chosen freely. It is useful to specify a
name with a reference to the sampling point involved (name of the company, equipment
name).
Menu “Project / Save Project”
Subject to change without notice
Fig 55
82
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Start-up and Configuration
Saving as a protocol
 Select “Communication / Upload all parameters from device” in the menu to select the
device and update device data.
Fig 56
Update device data (example)
 Select the “Diagnosis / Protocol” directory and click the button for the desired type of
registration.
Directory “Diagnosis / Protocol” (example)
Subject to change without notice
Fig 57
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83
Start-up and Configuration
The file name and storage location must be specified for export to a PDF file.
Fig 58
Specifying file name and storage location
Parameter protocol example
Parameter protocol DH SP200 (example)
Subject to change without notice
Fig 59
84
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Start-up and Configuration
Parameter protocol FWE200DH (example)
Subject to change without notice
Fig 60
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85
Start-up and Configuration
4.3.11
Starting normal measuring operation
Set the measuring system to “Measurement” mode after entering/modifying parameters.
To do this, switch to directory “Maintenance / Maintenance”, deactivate the “Maintenance
on/off” checkbox in the “Set Operating State” window and click “Set State” (→ Fig. 61).
Standard start-up is now completed.
Setting the operational state
Subject to change without notice
Fig 61
86
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Start-up and Configuration
4.4
Setting the Interface module parameters
The measuring system is delivered with an Interface module Modbus TCP as standard.
When desired, it can be swapped for an Interface module for Profibus DP V0 or Ethernet
(type 1) (→ p. 139, §7.3.6).
GSD file and measured value assignment are available for the Profibus DP
module on request.
4.4.1
Modbus TCP module
For detailed information concerning communication via Modbus, see the
“Modbus Organization” (www.modbus.org) documents, for example:
• MODBUS Messaging on TCP/IP Implementation Guide
• MODBUS APPLICATION PROTOCOL SPECIFICATION
• MODBUS over serial line specification and implementation guide
The register assignment is supplied as separate document with the Modbus module.
Check MCU settings
 Connect the MCU to the SOPAS ET program, select device file “MCU”, enter the level 1
password (→ p. 68, §4.3) and set the measuring system to “Maintenance” mode (→ p. 70,
§4.3.2).
 Switch to directory “Configuration / System Configuration” and check that the module
type in field “Interface Module / Interface Module” is set to “RS485”.
Fig 62
“Configuration / System Configuration” directory
Subject to change without notice
4.4.1.1
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87
Start-up and Configuration
 Switch to directory “Configuration / I/O Configuration / Interface Module” directory and
check that the interface is set according to Fig. 63 in the “RS 485 Interface Parameter”
field.
Check the interface
Subject to change without notice
Fig 63
88
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Start-up and Configuration
4.4.1.2
Installing the configuration program
A separate configuration program must be installed to set the customer requirements.
Administrator rights are required to install software.
System requirements
• Operating system: MS-Windows XP or higher
• Program NET Framework 4.0
• Program Windows Installer 3.1
Install the configuration program
 Connect the laptop/PC with the internet and enter “ftp://ftp.lantronix.com/pub/DeviceInstaller/Lantronix/4.3/”.
 Download the current configuration program.
Fig 64
Downloading the configuration program
It is possible that the version number changes
Select when the system
requirements are not fulfilled
(file size 99 MB)
Subject to change without notice
Select when the system
requirements are fulfilled (file
size 41 MB)
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89
Start-up and Configuration
4.4.1.3
Fig 65
Integrating the Modbus module in the network
 Start the “DeviceInstaller” program.
Starting the “DeviceInstaller”
 Wait for a few seconds while the program is searching for installed components.
 Select the “Tools/Options” menu.
Fig 66
“Tools/Options” menu
 If several networks are available, select the network interface with which the Modbus
module is connected.
Network connection(s) (example)
Subject to change without notice
Fig 67
90
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Start-up and Configuration
 Select the “Device/Search” menu and search for the Modbus module.
Fig 68
Searching for connected components
If no module has been found, check the network connection and search
again.
 Select the found module.
Fig 69
Selecting the module
Subject to change without notice
NOTICE:
Select the module only in the right window, not in the tree structure on the
left.
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Start-up and Configuration
 Click the “Assign IP” menu and perform the following steps.
Fig 70
Network assignment (address information is exemplary)

Step
1
2
92
Remark
Select the respective setting depending on the desired address assignment (automatic or
manual assignment)
Manual assignment: Enter the required network connection data here.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice

Start-up and Configuration
Fig 71
Defining the address settings

 Complete the assignment, then wait while the module is being configured and then
click “Finish”.
Completing the assignment
Subject to change without notice
Fig 72
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93
Start-up and Configuration
4.4.1.4
Fig 73
Configuring the Modbus module
 After confirming the address assignment with “Finish”, the following window is displayed:
“Telnet Configuration”
 Perform steps (1) to (3) in succession and confirm with <Enter>.
Fig 74
“Telnet Configuration”


Subject to change without notice

94
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Start-up and Configuration
 Define the serial and Modbus settings with the following entries.
Fig 75
Serial and Modbus settings
Enter ‘2‘
Confirm with <Enter> or enter ‘1‘
Confirm with <Enter> or enter ‘2‘
Enter ‘3‘ (if already present,
confirm with <Enter>)
Confirm with <Enter>
or enter ‘57600,8,N,1‘
Enter ‘3‘
Enter ‘4‘ (if already present,
confirm with <Enter>)
Confirm with <Enter>
or enter ‘N‘
Enter ‘1‘ (if already present,
confirm with <Enter>)
Confirm with <Enter>
or enter ‘1‘
Subject to change without notice
Enter ‘S‘
The Modbus module TCP is now configured.
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95
Start-up and Configuration
Checking the functional capability
 Enter 'ping' followed by the IP address under “Command Prompt” (“Start → Programs →
Accessories”) and check the module reply.
Fig 76
Correct reply from Modbus module
Subject to change without notice
4.4.1.5
96
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Start-up and Configuration
4.4.2
Setting the Ethernet module parameters
4.4.2.1
General information
NOTICE:
The risk of undesired access to the measuring system is inherent when
communicating via Ethernet.
 Operate the measuring system only behind suitable protection (e.g.,
Firewall).
The following steps are necessary to change the Modbus TCP module installed as
standard:
 Connect the MCU to the SOPAS ET program, select device file “MCU”, enter the level 1
password (→ p. 68, §4.3) and set the measuring system to “Maintenance” mode (→ p. 70,
§4.3.2).
 Switch to directory “Configuration / System Configuration” and select the module type
in field “Interface Module” under “Installed Interface Module”.
“Configuration / System Configuration” directory
Subject to change without notice
Fig 77
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97
Start-up and Configuration
4.4.2.2
Fig 78
Assigning the Ethernet module a new IP address
An IP address specified by the customer is entered at the factory when the address is
available when the device is ordered. If not, standard address 192.168.0.10 is set.
The following steps are necessary to change the address:
 Select directory “Configuration / I/O Configuration / Interface Module”.
 Set the desired network configuration in the “Ethernet Interface Configuration” field
and click “Reset module” under “Expansion module information”.
Directory “Configuration / I/O Configuration / Interface Module” (example)
Subject to change without notice
New address
98
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Start-up and Configuration
4.4.2.3
Fig 79
Assigning the new IP address to SOPAS ET
 Select the “Network Scan Assistant” tab and click “Network Configuration”.
 Select the “IP Communication” directory, set the “Enable IP Communication” field to
active and click “Add”.
 Enter the new IP address set in the “Configuration / I/O Configuration / Interface
Module” directory and confirm with “OK”.
Entering the IP address (example)
Subject to change without notice
 Click “Advanced” in the “IP communication” directory.
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99
Start-up and Configuration
 Select port address “2111” and confirm with “OK” (all other settings and values
according to Fig. 80).
Fig 80
Specifying the TCP port
 Activate only the required TCP port.
 To use a TCP port other than 2111 or 2112, activate the “Custom”
checkbox and enter the port number in the field below.
Subject to change without notice
 Select the “Network Scan Assistant” tab, click “Network Scan” and check that the set
address is displayed.
100
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Start-up and Configuration
Fig 81
Network scanning
Subject to change without notice
NOTICE:
Malfunctions in data transfers not caused by the measuring system can
occur during communication via Ethernet.
 The FWE200DH manufacturer assumes no responsibility for
malfunctions that may occur during equipment operation when
measured value transfers and their usage to control processes run solely
via Ethernet.
Increasing the value in the “Scan timeout” field from 500 ms to 3000 ms
can minimize communication problems.
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101
Start-up and Configuration
4. 5
Activating the backpurge option
This option must be activated with a codeword when retrofitted. The following steps are
then required:
 Select the “FWE200DH” device file, set the measuring system to “Maintenance” mode
and enter the level 1 password (→ p. 67, §4.2.4).
 Enter the codeword provided in field “Code for option ball valve” in directory “Configuration / Application parameter”.
 Switch to directory “Diagnosis / Device information” and check that display “Ball valve
hardware activated” is active in field “Configuration / States” (if not, activate according
to → p. 47, §3.3.4).
Activating the backpurge option (example)
Subject to change without notice
Fig 82
102
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Start-up and Configuration
4.6
Operating/setting parameters via the LC-Display
4.6.1
General information on use
The display and operating interface of the LC-Display contains the functional elements
shown in Fig. 83.
Fig 83
LC-Display functional elements
Status bar
Status LED
Display field
Current button
function
Control buttons
Button functions
The function shown depends on the Menu currently selected. Only the function shown in
the button is available.
Button
Diag
Back
Arrow 
Arrow 
Enter
Start
Save
Meas
Function
Display diagnostic information (warnings and errors during a start using the Main menu,
sensor information during a start using the Diagnostics menu → p. 104, Fig. 84)
Switch to higher level menu
Scroll up
Scroll down
Execution of the action selected with an arrow button (switch to a submenu, confirm
parameter selected during parameter setting)
Start an action
Store a changed parameter
Toggle between text and graphic display
Subject to change without notice
Display the contrast setting (after 2.5 s)
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103
Start-up and Configuration
4.6.2
Menu structure
Fig 84
LC-Display menu structure
*
Subject to change without notice
*
*: In operating state “Maintenance”
104
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Start-up and Configuration
Setting parameters
4.6.3.1
Sample gas temperature
 Set the system control (FWE200DH) to “Maintenance” (→ p. 104, Fig. 84) and activate
submenu “Parameter”.
 Choose the parameter to be entered and enter the default password “1234”.
 Set the calculated coefficients (→ p. 68, §4.3) using the “^” and/or “→” buttons and write
to the device with “Save” (confirm twice).
Fig 85
Changing the sample gas temperature
4.6.3.2
Analog outputs / inputs
 Set the control unit (MCU) to “Maintenance” (→ p. 104, Fig. 84) and activate submenu
“I/O Parameter”.
 Select the desired parameter and enter the default password “1234” using the “^”
(scrolls from 0 to 9) and/or “→” (moves the cursor to the right) buttons.
 Select the desired value using the “^” and/or “→” buttons and write it to the device with
“Save” (confirm 2x).
Subject to change without notice
4.6.3
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105
Start-up and Configuration
Fig 86
Menu structure for configuring analog outputs/inputs
*
Subject to change without notice
*: Not usable for FWE200DH (must be
set to “unlimited”)
106
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Start-up and Configuration
4.6.4
Using SOPAS ET to modify display settings
To modify factory settings, select device file “MCU” in the “Project Tree” window, enter the
level 1 password and select the “Configuration / Display Settings” directory.
Fig 87
Subject to change without notice
Window
Common Display
Settings
Overview Screen
Settings
Directory “Configuration / Display Settings” (example)
Entry field
Display language
Display Unit System
Bars 1 to 8
Value
Use AO scaling
Range low
Range high
Description
Language version shown on the LC-Display
Unit of measurement system used in displays
Sensor address for the first measured value bar in the graphic display
Measured value index for the respective measured value bar
When activated, the measured value bar is scaled to the associated analog
output. If not activated, define the limit values separately
Values for separate scaling of the measured value bar independent of the
analog output
The measured value assignment is listed in the bottom field.
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107
Subject to change without notice
Start-up and Configuration
108
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Maintenance
FWE200DH
5
Maintenance
Subject to change without notice
General information
Maintenance work
Putting the measuring system out of operation
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109
Maintenance
5. 1
General information
5.1.1
Maintenance intervals
The equipment operator must specify the maintenance intervals. The period depends on
existing operating parameters such as gas temperature and wetness, dust content and
state, how the equipment is run and ambient conditions. Therefore only general
recommendations can be made here.
Plan short intervals after measuring system startup that can then be adapted step by step
to meet the respective requirements.
The activities required and their completion must be documented by the operator in a
Maintenance Manual.
Recommendation
Interval
Work to be performed
1 week
Visual inspection
1 month
Check/clean jets in inlet nozzles of the thermo cyclone
Check/clean the ejector
Check/clean the suction nozzle
Check/clean the intermediate nozzle
3 months
Check/clean the sample gas probe
Check /clean the extraction and return hoses
Check/clean the swirl chamber (in the thermo cyclone)
6 months
Check/clean the optical surface in the measuring sensor
Check/clean the blower unit filter element
5.1.2
Maintenance contract
Scheduled maintenance work can be carried out by the equipment operator. Only qualified
personnel according to Section 1 should be allowed to do the work. If requested, all
maintenance activities can also be performed by SICK Service or an authorized Service
partner. SICK offers cost-effective maintenance and repair contracts. SICK carries out all
maintenance and repair work within the framework of these agreements. Any repairs will
be made by specialists onsite whenever possible.
Auxiliary means required






110
Water
Cleaning cloths (lint-free)
Optics cloth, cotton swabs
Jaw wrench, SW 7, 8, 13 and 19
Allen key, SW 7
Screwdriver with crosshead (middle size) and slot screwdriver (small).
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
5.1.3
Maintenance
5.1.4
Setting “Maintenance” mode
Take the following steps to set the measuring system to “Maintenance” mode before
starting maintenance work.
 Connect the measuring system to the laptop/PC using the USB cable and start SOPAS
ET.
 Click “Network Scan” in tab “Network Scan Assistant”, select device file “MCU” and
move it to window “Project Tree” (→ p. 66, §4.2.3.5).
 Switch to directory “Maintenance / Maintenance”, activate the “Maintenance on/off”
checkbox in the “Maintenance / Operation” group and click “Set State” (see → Fig. 88).
Fig 88
Setting “Maintenance” mode
Subject to change without notice
 “Maintenance” mode can also be set using the buttons on the LC-Display of
the control unit (→ p. 104, §4.6.2) or by connecting an external maintenance
switch to the terminals for Dig In2 (17, 18) in the control unit → p. 41,
§3.3.2).
 An automatic function check is not carried out during “Maintenance”.
 The value set for “Maintenance” is output on the analog output (→ p. 74,
§4.3.5). This also applies when a malfunction exists (signalized on the relay
output).
 When “Maintenance” mode is only set using SOPAS ET, this state is reset
after a voltage failure. The measuring system switches automatically to
“Measurement” after the operating voltage is switched on again.
Resume measuring operation after completing the work (deactivate the “Maintenance on/
off” checkbox in the “Maintenance / Operation” window and click “Set State”).
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111
Maintenance
5. 2
Maintenance work
NOTICE:
 During maintenance work, it must be possible to switch the power supply of
the FWE200DH off using a power isolating switch/circuit breaker in
accordance with EN61010-1.
 After completion of the work or for test purposes, the power supply may
only be activated again by the personnel who carried out the work and
complying with the valid safety regulations.
WARNING: Hazard through chemical compounds
Acids or bases can be created when deposits are dissolved when cleaning gascarrying parts (hoses, nozzles etc.) with water.
 Take suitable protective measures and use suitable protection devices.
 Observe the relevant safety regulations as well as the safety notices (→
p. 12, §1.3) during all work.
5.2.1
Preparatory work
 Remove the sample gas probe and close off the assembly opening with a blind flange.
WARNING: Hazard through gas and hot parts
Hot and/or aggressive gases can escape when removing and fitting the
sample gas probe as well as gas-carrying parts.
 Take suitable protective measures and use suitable protection devices.
 Observe the relevant safety regulations as well as the safety notices (→
p. 12, §1.3) during all work.
 Only remove or fit the sample gas probe on equipment with hazard
potential (higher internal duct pressure, hot or aggressive gases) when
the equipment is at a standstill.
 Switch off the fuses for heating bands 1 and 2 in the control unit.
The blower unit switches off when the average value of both heater temperatures is
below the warning threshold of the nominal temperature (default: 160°C - 10K =
150°C), at the latest at temperatures < 80°C.
 Switch the main switch in the control unit off and wait until hot parts have cooled down
sufficiently.
Main switch and fuses in the control unit
1
112
2
3
4
1
Main switch
2
FI circuit breaker
3
Fuse for heating band 1
4
Fuse for heating band 2
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Fig 89
Maintenance
5.2.2
Visual inspection
Subject to change without notice
 Check all hose connections for firm seat and leak tightness.
 Check the flow using the differential pressure (must be selected as measured value for
display on the LC-Display → p. 107, Fig. 87).
The value must be in the range 1 to 4 mbar when the blower is running.
If this is not the case:
 Check all gas-carrying parts for deposits and clean when necessary (see following
Section).
 Check running noise of the blower (must be within the normal frequency range); loud
noise signals a possible device failure.
 Put the measuring system out of operation (→ p. 121, §5.3) and then check the
blower unit.
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113
Maintenance
5.2.3
Cleaning the inlet nozzles on the thermo cyclone




Loosen hose clip (1) and pull extraction hose (2) off the connection of adapter (3).
Carefully loosen quick-release clamps (4) of the adapter and take the adapter off.
Pull jet (5) out of the adapter and remove O-ring (6)
Pull inlet nozzle (8) out of the thermo cyclone and remove O-rings (7).
The inlet nozzle may sit very tight.
 Clean the nozzles and O-rings with water.
Carefully remove solid deposits (when present) with suitable tools without damaging
the nozzles.
Fit new nozzles and/or O-rings when these are worn or damaged.
 Refit the O-rings and grease the two on the inlet nozzle with high-vacuum grease, insert
the nozzles, fit and fasten the adapter.
Position the adapter centered on the inlet nozzle and tighten both quickrelease clamps at the same time.
 Push the extraction hose onto the adapter connection and fasten with a hose clip.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
Fig 90
Inlet nozzlen
8
5
7
6
5
3
4
4
Subject to change without notice
3
1
2
114
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Maintenance
5.2.4
Cleaning the ejector
 Loosen hose clips (1) of return hose (2) and the hose to blower unit (3) on ejector (4)
and take the hoses off.
 Loosen quick-release clamps (5) on measuring cell (6) and take the ejector off.
 Press mixing tube (7) out of ejector housing (8).
 Clean the mixing tube, O-ring (9) and ejector housing with water.
Check parts for wear or damage and replace with new parts when necessary.
 Reassemble the ejector in reverse sequence and fit on the measuring cell.
 Connect the hoses and secure with hose clips.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
Fig 91
Ejector
6
7
9
4
8
5
2
3
1
Subject to change without notice
1
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
115
Maintenance
5.2.5
Cleaning the suction nozzle
 Loosen quick-release clamps (1) on measuring cell (2) and take ejector (3) off.
 Push lever (4) that locks the measuring sensor down and swivel the measuring sensor
out to the left.
 Press suction nozzle (5) downwards (e.g., with a light tap with the ball of the hand),
remove and clean it with water.
 Fit and fasten the ejector.
 Reassemble and lock the measuring sensor.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
Fig 92
Cleaning the suction nozzle
2
3
4
1
Subject to change without notice
5
116
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Maintenance
5.2.6
Cleaning the intermediate nozzle
 Pull the hose for differential pressure measurement of the connection (→ p. 116, Fig. 92).
 Push the lever that locks the measuring sensor down and swivel the measuring sensor
out to the left.
 Pull sample gas sensor (1) out of opening (2)
 Loosen fastening nut (3), turn intermediate nozzle (4), take it out of holder (5) and
clean with water.
 Check O-ring (6) and replace when necessary.
 Refit the intermediate nozzle, swivel the measuring sensor back in and lock.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
Fig 93
Cleaning the intermediate nozzle
5
3
2
3
4
6
1
5.2.7
Cleaning the sample gas probe and extraction and return hoses
Subject to change without notice
 Loosen the hose clips on both ends of the extraction and return hoses and pull the
hoses off.
 Clean the hoses and sample gas probe with water.
Replace worn or defective hoses with new ones (extraction hose Part No. 5313673,
return hose Part No. 5328761).
 Connect the hoses and secure with hose clips.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
117
Maintenance
5.2.8
Cleaning the swirl chamber
 Loosen fastening screws (1) of cover (2) and fold the cover down.
 Loosen fastening nuts (3) of cover (4) of swirl chamber (5) and take the cover with seal
(6) off.
 Clean the swirl chamber inside with water.
Carefully remove any deposits with suitable tools. Replace the swirl chamber with heavy
wear or damage with a new one (see Service Manual).
 Check the seal and baffle plate (7) and replace when necessary.
 Reassemble the thermo cyclone.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
Fig 94
Cleaning the swirl chamber
1
2
3
4
5
7
Subject to change without notice
6
118
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Maintenance
5.2.9
Cleaning the optical surfaces
Clean the optical surfaces when deposits can be seen or before contamination reaches the
maximum allowable contamination (limit value 30% for warning, 40% for malfunction). The
current contamination value can be read out on the LC-Display or in SOPAS ET.
 Loosen fastening screws (1) for cover (2) of the measuring cell and take the cover off.
 Carefully clean glass surfaces (3) and apertures (4) with cotton swabs, and also clean
light trap (5) when necessary.
Fig 95
Cleaning optical surfaces
1
3
2
4
1
3
5
Subject to change without notice
Higher contamination values (above approx. 10%) which cannot be reduced
even by cleaning several times indicate wear of the optical surfaces. Values
up to approx. 10% do not however have any influence on measuring
behavior and precision.
 Check the seal for the cover and replace when necessary.
 Fit the sample gas probe.
 If switched off, switch the fuses for the heating bands on and start the FWE200DH.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
119
Maintenance
5.2.10
Checking / replacing the filter element of the blower unit
Depending on the degree of contamination of the ambient air suctioned in, the operator
must check the filter element for contamination in intervals to be defined. Replace the
filter element when:
– Severe contamination (deposits on the filter surface) is visible.
– The purge air volume is reduced considerably as compared to operation with a new
filter.
The FWE200DH can continue running when cleaning the filter housing and replacing the
filter element
Work to be performed
Fig 96
Replacing the filter element
1
6
5
2
4
3
 Clean outside of filter housing (1).
 Loosen hose clip (2) and clamp hose (3) to a clean location.
NOTICE:
 Place the end of the hose in a safe place so that foreign objects cannot
be sucked in (this will cause irreparable damage to the blower), but do
not close the end of the hose! Unfiltered purge air penetrates the ejector
during this time.
 Press snap locks (4) together and take off filter housing cover (5).
 Remove filter element (6) with twisting-pulling movements.
 Clean the inside of the filter housing and the filter housing cover with a cloth and brush.
 Check the filter element and replace when necessary.
 Spare part: Filter element Micro-Top element C11 100, Part No. 5306091
 Insert the filter element with twisting-pressing movements.
Position the filter housing cover, ensuring that it is aligned correctly with the housing,
and snap the quick-releases into place.
 Connect the hose onto the filter outlet again and fasten with hose clip.
120
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
NOTICE:
 For wet cleaning, use only a water-soaked cloth and then dry the parts
well.
Maintenance
5.3
Putting the measuring system out of operation
The FWE200DH should remain in operation during short equipment standstills. For longer
standstills (as from approx. 1 week), we recommend putting the FWE200DH out of
operation.
NOTICE:
Put the FWE200DH out of operation immediately should the blower unit fail.
WARNING: Hazard through gas and hot parts
 Observe the relevant safety regulations as well as the safety notices in
Section 1 during all disassembly work.
 Take suitable protection measures against possible local hazards or
hazards arising from the equipment.
 Secure switches that should not be switched on again for safety reasons
with signs and safeguards to prevent unintentional switching.
Work to be performed
 Take the sample gas probe out of the gas duct.
WARNING: Hazard through gas and hot parts
 Only remove the sample gas probe on equipment with hazard potential (hot
or aggressive gases, higher internal duct pressure) when the equipment is
at a standstill.
Close off the assembly opening with a blind flange.
Loosen the hose connections on the sample gas probe.
Switch the main switch off.
After all hot parts have cooled down, remove the measuring and control unit and blower
unit, and store all components in a clean, dry location.
 Use suitable auxiliary means to protect the plug-in connectors against dirt and
moisture.
Subject to change without notice




FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
121
Subject to change without notice
Maintenance
122
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Troubleshooting and Error Handling
FWE200DH
6
Troubleshooting and Error Handling
Subject to change without notice
General information
Warning and error messages in SOPAS ET
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
123
Troubleshooting and Error Handling
6. 1
General information
Warning messages are output when internal limits for individual device functions/
components are reached or exceeded which can then lead to erroneous measured values
or an imminent failure of the measuring system.
Warning messages do not imply a malfunction of the measuring system. The
current measured value continues to be output on the analog output.
See the Service Manual for a detailed description of messages and options for
clearance.
6.1.1
Display of warning and malfunction messages
Warnings or device malfunctions are signaled by:
 Status relays (→ p. 42, §3.3.2.1).
 LC-Display of the measuring and control unit
“Maintenance request” or “Malfunction” displayed in the status line (→ p. 103, §4.6.1).
In addition, the respective LED goes on (“MAINTENANCE REQUEST” for warnings,
“FAILURE” for errors).
After pressing “Diag”, possible causes are shown as short information in the menu
“Diagnosis” after selecting the device (“DH SP200”, “FWE200DH”, “MCU”).
Fig 97
Display on the LC-Display
 In SOPAS ET
“Diagnosis / Error messages/warnings” provides detailed information on the current
device state.
124
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Display of current
warning or malfunction
Troubleshooting and Error Handling
6.1.2
Malfunctions
Symptom
No display on the
LCD
Possible cause
•
•
•
•
•
Analog output on
Live Zero
•
Main switch and/or fuses
switched off
Main supply voltage missing
Defective fuse
Cable to LC-Display not connected or damaged
Defective subassemblies




Check voltage supply.
Check connection cable.
Exchange fuse.
Contact SICK Service.
Device set to “Maintenance”
mode
Device has function fault(s)
 Check device status.
 Measuring range selected too large.
 Contact SICK Service.
Subject to change without notice
•
Action
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
125
Troubleshooting and Error Handling
Warning and error messages in SOPAS ET
6. 2
To display, connect the measuring system to SOPAS ET and start the device file “DH
SP200”, “FWE200DH” or “MCU” (→ p. 66, §4.2.3.5).
Move the mouse to the respective message to display more details on the significance of
individual messages in a separate window. Click on the display to view a short description
of possible causes and clearance for certain messages as “Context help”.
Select “Actual” or “Saved” in the “Error selection” or “Warnings selection” window to view
current or previous warning and malfunction messages recorded in error memory.
6.2.1
Measuring sensor
Fig 98
“Diagnosis / Error messages/Warnings” directory
Description
Display
Message
Description
Contamination
Received light intensity is
lower than the allowed limit
(→ p. 132, §7.1)
Span test
126
Possible cause
•
•
Action
Deposits on the optical
surfaces
Unclean purge air
 Clean optical surfaces ( → p. 119, §5.2.9).
 Check purge air filter (→ p. 120, §5.2.10)
 Contact SICK Service.
Deviation from setpoint value Sudden changes in measuring  Repeat the function check.
> ±2%.
conditions during determina-  Contact SICK Service.
tion of control values
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
Malfunctions listed below can probably be cleared onsite.
Troubleshooting and Error Handling
6.2.2
Measuring system
Fig 99
“Diagnosis / Error messages/Warnings” directory
Malfunctions listed below can probably be cleared onsite.
Subject to change without notice
Warning messages
Message
Description/possible cause
Action
Default value set
Measuring system set to delivery
parameters
 Configure the measuring system in accordance with requirements
Test operation activated
Automatic heating control and blower  Set the system to Measuring mode
unit control deactivated
CB2 fuse, heater 1
CB3 fuse, heater 2
Limit value exceeded
 Clean gas paths (→ p. 112, §5.2).
 Check/correct configuration (→ p. 71, §4.3.3.2).
 Contact SICK Service.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
127
Troubleshooting and Error Handling
Malfunction messages
Message
Description/possible cause
Action
Blower unit not
connected
Blower unit not connected or not
connected correctly (→ p. 45, §3.3.2.2).
 Check and correct connection
 Contact SICK Service.
Limit value
pressure
monitoring
Limit value underflown.
 Clean gas paths (→ p. 112, §5.2).
 Check/correct configuration (→ p. 71, §4.3.3.2).
 Contact SICK Service.
6.2.3
Control unit
Fig 100
“Diagnosis / Error messages/Warnings” directory
Subject to change without notice
Malfunctions listed below can probably be cleared onsite.
128
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Troubleshooting and Error Handling
Warning messages
Message
Description
No sensor found
Measuring sensor and/or system
control not recognized
Possible cause
•
•
Action
Communication prob-  Check system settings.
lems on RS485 line
 Check connection cable.
Supply voltage problems  Check voltage supply.
 Contact SICK Service.
Testmode enabled
MCU in “Test” mode.
 Deactivate “System Test” mode
(“Maintenance” directory)
Interface module
inactive
Interface module not configured
 Configure the interface module (→
p. 98, §4.4.2.2).
Malfunction messages
Message
Description
I/O range exceeded/ Analog output/input current
underflown
exceeded/underflown
Action
•
•
•
Measured value above
set range
Configuration error
Load does not match
specification
 Check input/output range values
with multimeter.
 Contact SICK Service.
Configuration error
Message
Description
AO configuration
Number of available and
configured analog outputs not
identical.
AI configuration
DO configuration
DI configuration
Sensor configuration
Interface Module
Number of available and
configured analog inputs not
identical.
Possible cause
•
•
•
•
•
•
Action
AO not configured
Connection error
Module failure
 Check configuration (→ p. 74,
§4.3.5).
 Contact SICK Service.
AI not configured
Connection error
Module failure
 Check configuration (→ p. 77,
§4.3.6).
 Contact SICK Service.
Sensor failure
Communication problems on RS485 line
 Check measuring sensor/system
control.
 Check connection cable.
 Contact SICK Service.
Module not configured
Connection error
Module failure
 Check configuration (→ p. 98,
§4.4.2.2).
 Contact SICK Service.
Not relevant for FWE200DH
Number of available sensors does
not match the number of sensors
connected.
No communication via Interface
module
•
•
•
•
Subject to change without notice
•
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
129
Subject to change without notice
Troubleshooting and Error Handling
130
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Specifications
FWE200DH
7
Specifications
Subject to change without notice
Technical Data
Dimensions, Part Nos.
Options
Consumable parts for 2-years operation
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
131
Specifications
Technical Data
Measuring Parameters
Measured variable
Measuring range (freely
adjustable)
Measuring precision
Reaction time
Application Data
Gas temperature
Internal duct pressure
Gas wetness
Gas velocity
Ambient temperature
Function Check
Automatic self-test
Manual linearity check
Displays
LC-Display on control cabinet
Output Signals
Analog outputs
Relay outputs
Input Signals
Analog inputs
Digital inputs
Communication Interfaces
USB 1.1
RS485
Interface module
Power Supply
Voltage supply
Power consumption
Dimensions (W x H x D), Weight
Measuring and control unit
Sample gas probe
Blower unit
Miscellaneous
Protection class
Laser
Blower feed amount
132
Scattered light intensity
Dust concentration output in mg/m³ after gravimetric comparison measurement
Smallest range: 0 ... 5 mg/m³
Largest range:
200 mg/m³
higher on request, in-between freely configurable
±2% of upper measuring range value
0.1 ... 600 s; freely selectable
Max. 120 °C for PVDF probes
Max. 220 °C for Hastelloy probes (higher on request)
± 20 hPa
Max. 10 g water per m³ (weight share 1%) as fluid share without water vapor (higher on request)
7 to 30 m/s
-20 ... +50°C
Housing necessary for other temperature limits
-20 ... +45°C
Intake temperature for purge air
Linearity, drift, aging, contamination
Contamination limit value: From 30% warning: From 40% malfunction
Using a reference filter (test equipment for linearity test)
Displays measured values and system states
3 outputs 0/2/4 ... 22 mA, max. load 750 Ω; electrically isolated
5 potential-free outputs (changeover contacts) for status signals; load 48 V, 1 A
6 inputs 0...20 mA (standard; without electric isolation); precision ± 0.1 mA
8 inputs for connecting potential-free contacts (→ p. 42, §3.3.2.1)
For measured value inquiries and software updates per PC/laptop using the operating program
For connecting the remote unit option
For communication with higher-level control systems, Modbus TCP as standard
Alternately Profibus DP, Ethernet
115 / 230 V AC, 50 / 60Hz
Max. 1.7 kW (standard version without extraction hose option)
Approx. 820 x 730 x 300 mm; approx. 65 kg
Length 730 mm (NL 600 mm); 1330 mm (NL 1200 mm); max. 15 kg
550 mm x 550 mm x 258 mm; with weatherproof cover 605 mm x 550 mm x 350 mm; approx.
16 kg
IP 54 (electronic housing IP 65)
Laser class 1 in operating state, laser class 2 in open state;
Capacity < 1 mW;
wavelength between 640 nm and 660 nm
Approx. 30 ... 40 m³/h
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
7. 1
Specifications
Compliances
The technical version of this device complies with the following EU directives and EN standards:
 EU Directive: LVD (Low Voltage Directive)
 EU Directive: EMC (Electromagnetic Compatibility)
Applied EN standards:
 EN 61010-1, Safety requirements for electrical equipment for measurement, control
and laboratory use
 EN 61326, Electrical equipment for measurement technology, control technology and
laboratory use - EMC requirements
 EN 14181, Emissions from stationary sources - Quality assurance for AMS
 EN 15267-3: Certification of automated measuring systems - Part 3
Measuring system FWE200DH meets the requirement for EMC regarding emission and
immunity for industrial environments.
Electrical protection
 Insulation: Protection class 1 in accordance with EN 61010-1.
 Contamination: The device operates safely in an environment up to degree of contamination 2 according to EN 61010-1 (usual, not conductive contamination and temporary
conductivity by occasional moisture condensation).
 Electrical energy: The wiring system to the power supply voltage of the system must be
installed and fused according to the relevant regulations.
Subject to change without notice
Approvals
The measuring system is performance-tested in accordance with EN 15267.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
133
Specifications
7. 2
Dimensions, Part Nos.
All dimensions in mm.
Sample gas probe
Fig 101
Sample gas probe
DN
Ø 50
Ø 32
Ø2
00
7.2.1
,5°
22
Nominal length NL
NL = 600, 1200
DN = 14, 18, 23
Designation
Sample gas probe NL 600 PVDF var.
Sample gas probe NL1200 PVDF var.
Sample gas probe NL 600 Hastelloy var.
Sample gas probe NL1200 Hastelloy var.
7.2.2
Flange with tube
Fig 102
Flange with tube
Part No.
2074811
2075029
2075038
2075039
Ro 139.7 x 4
Flange DIN 2631 ND6, NW 125
Ø 200
(152)
Ø 18
Designation
Flange with tube D139ST200
Flange with tube D139SS200
134
Material
St37
1.4571
Part No.
7047616
7047641
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Subject to change without notice
200
Specifications
7.2.3
Measuring and control unit
Fig 103
Measuring and control unit
813
286
650
650
30
722
78
Ø 14
Part No.
1066190
1068441
1069950
1068461
1069591
1069592
1069593
1069594
1069595
1069596
1069597
1069598
Subject to change without notice
Designation
Measuring and control unit FWE200DH-NNJ
Measuring and control unit FWE200DH-NNE
Measuring and control unit FWE200DH-NNP
Measuring and control unit FWE200DH-BNJ
Measuring and control unit FWE200DH-BNE
Measuring and control unit FWE200DH-BNP
Measuring and control unit FWE200DH-NHJ
Measuring and control unit FWE200DH-NHE
Measuring and control unit FWE200DH-NHP
Measuring and control unit FWE200DH-BHJ
Measuring and control unit FWE200DH-BHE
Measuring and control unit FWE200DH-BHP
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
135
Specifications
Blower unit
Fig 104
Blower unit
470
40
ø 14
470
550
7.2.4
40
258
550
Part No.
1067951
Subject to change without notice
Designation
Blower unit with blower 2BH1100, filter, purge air hose length 10 m
136
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Specifications
7.3
Options
7.3.1
Remote unit
Fig 105
Remote unit
210
120
300
320
340
160
Ø8
Part No.
2075567
2075568
Subject to change without notice
Designation
Remote unit
Remote unit with integrated wide-range power pack
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
137
Specifications
Fig 106
Frame
(Measuring and
control unit)
1855
(250)
650
(1970)
Frame
650
7.3.2
(Blower unit)
140
470
1180
470
1000
(Flange with
tube)
800
Part No.
7047617
Subject to change without notice
Designation
Frame
450
500
Ø 15
138
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Specifications
7.3.3
Weatherproof cover for blower unit
Fig 107
Weatherproof cover for blower unit
550
245
550
350
605
Designation
Weatherproof cover for purge air unit
7.3.4
Measuring system
Designation
Backpurge unit option
Cover at the bottom
Option, heated extraction hose, length 4 m (3 m heated)
7.3.5
Part No.
2073682
2074595
2075575
Interface module
Designation
Interface module, Profibus module DP V0
Interface module, Ethernet type 1
7.3.6
Part No.
5306108
Part No.
2040961
2040965
Device check accessories
Part No.
2072204
Subject to change without notice
Designation
Test equipment for linearity test FWE200DH
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
139
Specifications
7. 4
Consumable parts for 2-years operation
7.4.1
Measuring sensor
Designation
Optics cloth
7.4.2
Number
4
Part no.
4003353
Number
4
Part no.
5306090
Blower unit
Subject to change without notice
Designation
Filter element, Europiclon 3000 l/min
140
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Annex
FWE200DH
8
Annex
Subject to change without notice
Password
Standard settings FWE200DH
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
141
Annex
8. 1
Password
Fig. 108
Password
Passwort „Autorisierter Bediener“
Nach dem Start des Bedien- und Parametrierprogrammes SOPAS ET sind nur die Programmfunktionen verfügbar, die keinen Einfluss auf die Gerätefunktion haben.
Nicht eingewiesenes Personal kann keine Änderungen der Parameter vornehmen.
Zur Nutzung des erweiterten Funktionsumfanges wird das
Passwort
sickoptic
benötigt.
Falls zur Eingabe eine falsche Taste gedrückt wird, muß das Fenster geschlossen und
anschließend die Passworteingabe wiederholt werden.
Password "Authorized operator"
After the start of the SOPAS ET operating and parameterization program, only menus
are available which have no effect on the functioning of the device.
Untrained personnel cannot alter the device parameters. To access the extended range
of functions the
password
sickoptic
must be entered
If a wrong key is pressed when entering the password, the window must be closed and
then the entering repeated.
Subject to change without notice
The password is part of the system documentation delivered with the measuring system.
142
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
Annex
8.2
Standard settings FWE200DH
Subject to change without notice
The protocols for parameter settings when delivered (factory settings, → p. 69, §4.3.1) are
part of the system documentation delivered with the measuring system and are therefore
not described separately in these Operating Instructions.
FWE200DH · Operating Instructions · 8016686 V 1.0 · © SICK AG
143
8016686/2014-05/V1.0/Subject to change without notice
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